Fluid-Absorbent Articles

ABSTRACT

The present invention relates to a process for producing fluid-absorbent cores, comprising mixing a fibrous material and fluid-absorbent polymer particles having low moisture content and low apparent density and pressing the obtained mixture under specific conditions.

The present invention relates to a process for producing fluid-absorbentcores, comprising mixing a fibrous material and fluid-absorbent polymerparticles having low moisture content and low apparent density andpressing the obtained mixture under specific conditions.

The preparation of fluid-absorbent polymers is described in themonograph “Modern Superabsorbent Polymer Technology”, F. L. Buchholz andA. T. Graham, Wiley-VCH, 1998, on pages 71 to 103.

Fluid-absorbent articles are also described in the monograph “ModernSuperabsorbent Polymer Technology” on pages 252 to 258.

The preparation of spherical fluid-absorbent polymer particles bypolymerizing droplets of a monomer solution is described, for example,in EP 0 348 180 A1, WO 96/40427 A1, U.S. Pat. No. 5,269,980, DE 103 14466 A1, DE 103 40 253 A1, DE 10 2004 024 437 A1, DE 10 2005 002 412 A1,DE 10 2006 001 596 A1, WO 2008/009580 A1, WO 2008/009598 A1, WO2008/009599 A1 and WO 2008/009612 A1, and also the prior PCTapplications PCT/EP2008/051336 and PCT/EP2008/051353.

Polymerization of monomer solution droplets in a gas phase surroundingthe droplets (“dropletization polymerization”) affords roundfluid-absorbent polymer particles of high mean sphericity (mSPHT). Themean sphericity is a measure of the roundness of the polymer particlesand can be determined, for example, with the Camsizer® image analysissystem (Retsch Technology GmbH; Haan; Germany). The fluid-absorbentpolymer particles obtained by dropletization polymerization aretypically hollow spheres.

It was an object of the present invention to provide fluid-absorbentarticles with improved properties, i.e. comprising fluid-absorbentpolymer particles having an absorption under a load of 49.2 g/cm²(AUHL), low migration of the fluid-absorbent polymer particles withinthe fluid-absorbent core and a durable fluid-absorbent core.

The object is achieved by a process for preparing a fluid-absorbentcore, comprising

-   (i) mixing of a fibrous material and 10 to 95% by weight of    fluid-absorbent polymer particles having a particle size of less    than 1000 μm, a medium particle size of 200 to 600 μm, a moisture    content of less than 20% by weight, a mean sphericity of at least    0.84 and a floating particle fraction (FPF) of at least 10%, and-   (ii) pressing the obtained mixture,    wherein the pressing (ii) is performed that the core (C) has a    density of

D<β×0.14 g/cm³+0.18 g/cm³

wherein D is the density of the core (C) and β is the weight fraction offluid-absorbent polymer particles in the core (C).

The fluid-absorbent polymer particles having a high floating particlefraction (FPF) are pressure sensitive and deteriorate during thepressing ii). On the other hand, the pressing ii) is necessary to getdurable fluid-absorbent cores with optimized capillary effects(capillary force and flow speed).

Ultrathin fluid-absorbent articles require fluid-absorbing polymerparticles without coarse particles having rough edges, since coarseparticles having rough edges would be perceptible and are rejected bythe consumer. Due to the necessary grinding during production,fluid-absorbent polymer particles prepared by gel polymerization havesuch rough edges. Thus, round fluid-absorbent polymer particles preparedby inverse suspension polymerization are preferred.

The fluid-absorbent polymer particles prepared by inverse suspensionpolymerization have a low floating particle fraction (FPF) or highapparent density. The result of the low floating particle fraction (FPF)in combination with the roundness of the particles is an increasedtendency of the fluid-absorbent polymer particles to migrate within thefluid-absorbent core.

Fluid-absorbent particles prepared by dropletization polymerization arehollow spheres and combines roundness and a high floating particlefraction (FPF).

Another object of the present invention is achieved by fluid-absorbentarticles, comprising

-   -   (A) an upper liquid-pervious layer,    -   (B) a lower liquid-impervious layer and    -   (C) a fluid-absorbent core between the layer (A) and the layer        (B), comprising a fibrous material and 10 to 95% by weight        fluid-absorbent polymer particles having a particle size of less        than 1000 μm, a medium particle size of 200 to 600 μm, a        moisture content of less than 20% by weight, a mean sphericity        of at least 0.84 and a floating particle fraction (FPF) at least        10%,        wherein the core (C) has a density of

D<β×0.14 g/cm³+0.18 g/cm³

wherein D is the density of the core (C) and β is the weight fraction offluid-absorbent polymer particles in the core (C).

The fluid-absorbent core (C) comprises of a fibrous material andpreferably 20 to 80% by weight, more preferably 25 to 70% by weight,most preferably 30 to 60% by weight, of fluid-absorbent polymerparticles.

The fluid-absorbent polymer particles useable for the inventivefluid-absorbent articles have a moisture content of preferably less than19% by weight, more preferably less than 18% by weight, most preferablyless than 17% by weight.

The fluid-absorbent polymer particles useable for the inventivefluid-absorbent articles have a mean sphericity of preferably at least0.86, more preferably at least 0.88 and most preferably at least 0.9.The sphericity (SPHT) is defined as

${{SPHT} = \frac{4\pi \; A}{U^{2}}},$

where A is the cross-sectional area and U is the cross-sectionalcircumference of the polymer particles. The mean sphericity is thevolume-average sphericity.

The mean sphericity can be determined, for example, with the Camsizer®image analysis system (Retsch Technolgy GmbH; Haan; Germany);

For the measurement, the product is introduced through a funnel andconveyed to the falling shaft with a metering channel. While theparticles fall past a light wall, they are recorded selectively by acamera. The images recorded are evaluated by the software in accordancewith the parameters selected.

To characterize the roundness, the parameters designated as sphericityin the program are employed. The parameters reported are the meanvolume-weighted sphericities, the volume of the particles beingdetermined via the equivalent diameter xc_(min). To determine theequivalent diameter xc_(min), the longest chord diameter for a total of32 different spatial directions is measured in each case. The equivalentdiameter xc_(min) is the shortest of these 32 chord diameters. To recordthe particles, the so-called CCD-zoom camera (CAM-Z) is used. To controlthe metering channel, a surface coverage fraction in the detectionwindow of the camera (transmission) of 0.5% is predefined.

Fluid-absorbent polymer particles with relatively low sphericity areobtained by reverse suspension polymerization when the polymer beads areagglomerated during or after the polymerization.

The fluid-absorbent polymer particles prepared by customary solutionpolymerization (gel polymerization) are ground and classified afterdrying to obtain irregular polymer particles. The mean sphericity ofthese polymer particles is between approx. 0.72 and approx. 0.78.

The fluid-absorbent polymer particles useable for the inventivefluid-absorbent articles have a floating particle fraction (FPF) ofpreferably at least 12%, more preferably at least 13%, most preferablyat least 14%.

The fluid-absorbent polymer particles useable for the inventivefluid-absorbent articles have a moisture content of preferably at least8% by weight, more preferably at least 10% by weight, most preferably atleast 12% by weight.

The fluid-absorbent polymer particles useable for the inventivefluid-absorbent articles have a content of hydrophobic solvent ofpreferably less than 0.005% by weight, more preferably less than 0.002%by weight and most preferably less than 0.001% by weight. The content ofhydrophobic solvent can be determined by gas chromatography, for exampleby means of the headspace technique.

Fluid-absorbent polymer particles which have been obtained by reversesuspension polymerization still comprise typically approx. 0.01% byweight of the hydrophobic solvent used as the reaction medium.

The fluid-absorbent polymer particles useable for the inventivefluid-absorbent articles have a dispersant content of typically lessthan 1% by weight, preferably less than 0.5% by weight, more preferablyless than 0.1% by weight and most preferably less than 0.05% by weight.

Fluid-absorbent polymer particles which have been obtained by reversesuspension polymerization still comprise typically at least 1% by weightof the dispersant, i.e. ethyl-cellulose, used to stabilize thesuspension.

The fluid-absorbent core (C) contains preferably at least 9 g, morepreferably at least 10 g, most preferably at least 12 g, of thefluid-absorbent polymer particles.

The fluid-absorbent polymer particles useable for the fluid-absorbentarticles according to the invention have a centrifuge retention capacity(CRC) of typically at least 10 g/g, preferably at least 15 g/g,preferentially at least 20 g/g, more preferably at least 25 g/g, mostpreferably at least 30 g/g. The centrifuge retention capacity (CRC) ofthe fluid-absorbent polymer particles is typically less than 50 g/g.

The fluid-absorbent polymer particles useable for the fluid-absorbentarticles according to the invention have a saline flow conductivity(SFC) of typically at least 5×10⁻⁷ cm³s/g, preferably at least 15×10⁻⁷cm³s/g, preferably at least 35×10⁻⁷ cm³s/g, more preferably at least120×10⁻⁷ cm³s/g, most preferably at least 200×10⁻⁷ cm³s/g. The salineflow conductivity (SFC) of the fluid-absorbent polymer particles istypically less than 500×10⁻⁷ cm³s/g.

In a preferred embodiment of the present invention, the fluid-absorbentcore comprises of 10 to 50% by weight of fluid-absorbent polymerparticles having a centrifuge retention capacity (CRC) from 32 to 60g/g.

In an other preferred embodiment of the present invention, thefluid-absorbent core comprises of 40 to 80% by weight of fluid-absorbentpolymer particles having a saline flow conductivity (SFC) from 35 to100×10⁻⁷ cm³s/g.

In an other preferred embodiment of the present invention, thefluid-absorbent core comprises of 55 to 95% by weight of fluid-absorbentpolymer particles having a saline flow conductivity (SFC) from 50 to150×10⁻⁷ cm³s/g.

DETAILED DESCRIPTION OF THE INVENTION A. Definitions

As used herein, the term “fluid-absorbent composition” refers to acomponent of the fluid-absorbent article which is primarily responsiblefor the fluid handling of the fluid-absorbent article includingacquisition, transport, distribution and storage of body fluids.

As used herein, the term “fluid-absorbent core” refers to afluid-absorbent composition comprising a fibrous material andfluid-absorbent polymer particles. The fluid-absorbent core is primarilyresponsible for the fluid handling of the fluid-absorbent articleincluding acquisition, transport, distribution and storage of bodyfluids.

As used herein, the term “layer” refers to a fluid-absorbent compositionwhose primary dimension is along its length and width. It should beknown that the term “layer” is not necessarily limited to single layersor sheets of the fluid-absorbent composition. Thus a layer can compriselaminates, composites, combinations of several sheets or webs ofdifferent materials.

As used herein, the term “x: dimension” refers to the length, and theterm “y-dimension” refers to the width of the fluid-absorbentcomposition, layer, core or article. Generally, the term “x-y dimension”refers to the plane, orthogonal to the height or thickness of thefluid-absorbent composition, layer, core or article.

As used herein, the term “z-dimension” refers to the dimensionorthogonal to the length and width of the fluid-absorbent composition,layer, core or article. Generally, the term “z-dimension” refers to theheight of the fluid-absorbent composition.

As used herein, the term “chassis” refers to fluid-absorbent materialcomprising the upper liquid-pervious layer and the lowerliquid-impervious layer.

As used herein, the term “basis weight” indicates the weight of thefluid-absorbent core per square meter and it includes the chassis of thefluid-absorbent article. The basis weight is determined at discreteregions of the fluid-absorbent core: the front overall average is thebasis weight of the fluid-absorbent core 5.5 cm forward of the center ofthe core to the front distal edge of the core; the insult zone is thebasis weight of the fluid-absorbent core 5.5 cm forward and 0.5 cmbackwards of the center of the core; the back overall average is thebasis weight of the fluid-absorbent core 0.5 cm backward of the centerof the core to the rear distal edge of the core.

As used herein, the term “density” indicates the weight of thefluid-absorbent core per volume and it includes the chassis of thefluid-absorbent article. The density is determined at discrete regionsof the fluid-absorbent core: the front overall average is the density ofthe fluid-absorbent core 5.5 cm forward of the center of the core to thefront distal edge of the core; the insult zone is the density of thefluid-absorbent core 5.5 cm forward and 0.5 cm backwards of the centerof the core; the back overall average is the density of thefluid-absorbent core 0.5 cm backward of the center of the core to therear distal edge of the core.

Further, it should be understood, that the term “upper” refers tofluid-absorbent compositions which are nearer to the wearer of thefluid-absorbent article. Generally, the topsheet is the nearestcomposition to the wearer of the fluid-absorbent article, hereinafterdescribed as “upper liquid-pervious layer”. Contrarily, the term “lower”refers to fluid-absorbent compositions which are away from the wearer ofthe fluid-absorbent article. Generally, the backsheet is the compositionwhich is furthermost away from the wearer of the fluid-absorbentarticle, hereinafter described as “lower liquid-impervious layer”.

As used herein, the term “liquid-pervious” refers to a substrate, layeror a laminate thus permitting liquids, i.e. body fluids such as urine,menses and/or vaginal fluids to readily penetrate through its thickness.

As used herein, the term “liquid-impervious” refers to a substrate,layer or a laminate that does not allow body fluids to pass through in adirection generally perpendicular to the plane of the layer at the pointof liquid contact under ordinary use conditions.

Fluid-absorbent articles comprising more than one fluid-absorbent core,in a preferred manner comprising a double-core system including an uppercore and a lower core, hereinafter called “primary core” and “secondarycore”.

As used herein, the term “hydrophilic” refers to the wettability offibers by water deposited on these fibers. The term “hydrophilic” isdefined by the contact angle and surface tension of the body fluids.According to the definition of Robert F. Gould in the 1964 AmericanChemical Society publication “Contact angle, wettability and adhesion”,a fiber is referred to as hydrophilic, when the contact angle betweenthe liquid and the fiber, especially the fiber surface, is less than 90°or when the liquid tends to spread spontaneously on the same surface.

Contrarily, term “hydrophobic” refers to fibers showing a contact angleof greater than 90° or no spontaneously spreading of the liquid acrossthe surface of the fiber.

As used herein, the term “section” or “zone” refers to a definite regionof the fluid-absorbent composition.

As used herein, the term “article” refers to any three-dimensional solidmaterial being able to acquire and store fluids discharged from thebody. Preferred articles according to the present invention aredisposable fluid-absorbent articles that are designed to be worn incontact with the body of a user such as disposable fluid-absorbentpantiliners, sanitary napkins, catamenials, incontinence inserts/pads,diapers, training pant diapers, breast pads, interlabial inserts/padsand the like.

As used herein, the term “body fluids” refers to any fluid produced anddischarged by human or animal body, such as urine, mentrual fluids,faeces, vaginal secretions and the like.

B. Fluid-Absorbent Polymer Particles

The fluid-absorbent polymer particles are preferably prepared bypolymerizing droplets of a monomer solution comprising

-   -   a) at least one ethylenically unsaturated, acid group-bearing        monomer which may be at least partly neutralized,    -   b) at least one crosslinker,    -   c) at least one initiator,    -   d) optionally one or more ethylenically unsaturated monomers        copolymerizable with the monomers mentioned under a),    -   e) optionally one or more water-soluble polymers and    -   f) water,

in a gas phase surrounding the droplets, wherein the polymerization inthe droplet taking place in homogeneous phase.

The fluid-absorbent polymer particles are typically insoluble in water.

The monomers a) are preferably water-soluble, i.e. the solubility inwater at 23° C. is typically at least 1 g/100 g of water, preferably atleast 5 g/100 g of water, more preferably at least 25 g/100 g of water,most preferably at least 35 g/100 g of water.

Suitable monomers a) are, for example, ethylenically unsaturatedcarboxylic acids such as acrylic acid, methacrylic acid and itaconicacid. Particularly preferred monomers are acrylic acid and methacrylicacid. Very particular preference is given to acrylic acid.

Further suitable monomers a) are, for example, ethylenically unsaturatedsulfonic acids such as styrenesulfonic acid and2-acrylamido-2-methylpropanesulfonic acid (AMPS).

Impurities may have a strong impact on the polymerization. Preference isgiven to especially purified monomers a). Useful purification methodsare disclosed in WO 2002/055469 A1, WO 2003/078378 A1 and WO 2004/035514A1. A suitable monomer a) is according to WO 2004/035514 A1 purifiedacrylic acid having 99.8460% by weight of acrylic acid, 0.0950% byweight of acetic acid, 0.0332% by weight of water, 0.0203 by weight ofpropionic acid, 0.0001% by weight of furfurals, 0.0001% by weight ofmaleic anhydride, 0.0003% by weight of diacrylic acid and 0.0050% byweight of hydroquinone monomethyl ether.

The content of acrylic acid and/or salts thereof in the total amount ofmonomers a) is preferably at least 50 mol %, more preferably at least 90mol %, most preferably at least 95 mol %.

The acid groups of the monomers a) are typically partly neutralized,preferably to an extent of from 25 to 85 mol %, preferentially to anextent of from 50 to 80 mol %, more preferably from 60 to 75 mmol %, forwhich the customary neutralizing agents can be used, preferably alkalimetal hydroxides, alkali metal oxides, alkali metal carbonates or alkalimetal hydrogen carbonates, and mixtures thereof. Instead of alkali metalsalts, it is also possible to use ammonia. Sodium and potassium areparticularly preferred as alkali metals, but very particular preferenceis given to sodium hydroxide, sodium carbonate or sodium hydrogencarbonate, and mixtures thereof. Typically, the neutralization isachieved by mixing in the neutralizing agent as an aqueous solution, asa melt or preferably also as a solid. For example, sodium hydroxide witha water content significantly below 50% by weight may be present as awaxy material having a melting point above 23° C. In this case, meteredaddition as piece material or melt at elevated temperature is possible.

The monomers a) comprise typically polymerization inhibitors, preferablyhydroquinone monoethers, as inhibitor for storage.

The monomer solution comprises preferably up to 250 ppm by weight, morepreferably not more than 130 ppm by weight, most preferably not morethan 70 ppm by weight, preferably not less than 10 ppm by weight, morepreferably not less than 30 ppm by weight and especially about 50 ppm byweight of hydroquinone monoether, based in each case on acrylic acid,with acrylic acid salts being counted as acrylic acid. For example, themonomer solution can be prepared using acrylic acid having anappropriate hydroquinone monoether content.

Preferred hydroquinone monoethers are hydroquinone monomethyl ether(MEHQ) and/or alpha-tocopherol (vitamin E).

Suitable crosslinkers b) are compounds having at least two groupssuitable for crosslinking. Such groups are, for example, ethylenicallyunsaturated groups which can be polymerized by a free-radical mechanisminto the polymer chain and functional groups which can form covalentbonds with the acid groups of monomer a). In addition, polyvalent metalions which can form coordinate bond with at least two acid groups ofmonomer a) are also suitable crosslinkers b).

The crosslinkers b) are preferably compounds having at least twofree-radically polymerizable groups which can be polymerized by afree-radical mechanism into the polymer network. Suitable crosslinkersb) are, for example, ethylene glycol dimethacrylate, diethylene glycoldiacrylate, polyethylene glycol diacrylate, allyl methacrylate,trimethylolpropane triacrylate, triallylamine, tetraallylammoniumchloride tetraallyloxyethane, as described in EP 0 530 438 A1, di- andtriacrylates, as described in EP 0 547 847 A1, EP 0 559 476 A1, EP 0 632068 A1, WO 93/21237 A1, WO 2003/104299 A1, WO 2003/104300 A1, WO2003/104301 A1 and in DE 103 31 450 A1, mixed acrylates which, as wellas acrylate groups, comprise further ethylenically unsaturated groups,as described in DE 103 314 56 A1 and DE 103 55 401 A1, or crosslinkermixtures, as described, for example, in DE 195 43 368, DE-A-196 46 484A1, WO 90/15830 A1 and WO 2002/32962 A2.

Suitable crosslinkers b) are in particular pentaerythritol triallylether, tetraallyloxyethane, N,N′-methylenebisacrylamide, 15-tuplyethoxylated trimethylolpropane, polyethylene glycol diacrylate,trimethylolpropane triacrylate and triallylamine.

Very particularly preferred crosslinkers b) are the polyethoxylatedand/or -propoxylated glycerols which have been esterified with acrylicacid or methacrylic acid to give di- or triacrylates, as described, forexample in WO 2003/104301 A1. Di- and/or triacrylates of 3- to 10-tuplyethoxylated glycerol are particularly advantageous. Very particularpreference is given to di- or triacrylates of 1- to 5-tuply ethoxylatedand/or propoxylated glycerol. Most preferred are the triacrylates of 3-to 5-tuply ethoxylated and/or propoxylated glycerol and especially thetriacrylate of 3-tuply ethoxylated glycerol.

The amount of crosslinker b) is preferably from 0.05 to 1.5% by weight,more preferably from 0.1 to 1% by weight, most preferably from 0.3 to0.6% by weight, based in each case on monomer a). On increasing theamount of crosslinker b) the centrifuge retention capacity (CRC)decreases and the absorption under a pressure of 21.0 g/cm² (AUL) passesthrough a maximum.

The initiators c) used may be all compounds which disintegrate into freeradicals under the polymerization conditions, for example peroxides,hydroperoxides, hydrogen peroxide, persulfates, azo compounds and redoxinitiators. Preference is given to the use of water-soluble initiators.In some cases, it is advantageous to use mixtures of various initiators,for example mixtures of hydrogen peroxide and sodium or potassiumperoxodisulfate. Mixtures of hydrogen peroxide and sodiumperoxodisulfate can be used in any proportion.

Particularly preferred initiators c) are azo initiators such as2,2″-azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride and2,2″-azobis[2-(5-methyl-2-imidazolin-2-yl)propane]dihydrochloride, andphotoinitiators such as 2-hydroxy-2-methylpropiophenone and1-[4-(2-hydroxyethoxy)phenyl]-2-hydroxy-2-methyl-1-propan-1-one, redoxinitiators such as sodium persulfate/hydroxymethylsulfinic acid,ammonium peroxodisulfate/hydroxymethylsulfinic acid, hydrogenperoxide/hydroxymethylsulfinic acid, sodium persulfate/ascorbic acid,ammonium peroxodisulfate/ascorbic acid and hydrogen peroxide/ascorbicacid, photoinitiators such as1-[4-(2-hydroxyethoxy)phenyl]-2-hydroxy-2-methyl-1-propan-1-one, andmixtures thereof.

The initiators are used in customary amounts, for example in amounts offrom 0.001 to 5% by weight, preferably from 0.01 to 2% by weight, basedon the monomers a).

Examples of ethylenically unsaturated monomers c) which arecopolymerizable with the monomers a) are acrylamide, methacrylamide,hydroxyethyl acrylate, hydroxyethyl methacrylate, dimethylaminoethylacrylate, dimethylaminoethyl methacrylate, dimethylaminopropyl acrylateand diethylaminopropyl methacrylate.

Useful water-soluble polymers d) include polyvinyl alcohol,polyvinylpyrrolidone, starch, starch derivatives, modified cellulosesuch as methylcellulose or hydroxyethylcellulose, gelatin, polyglycolsor polyacrylic acids, preferably starch, starch derivatives and modifiedcellulose.

For optimal action, the preferred polymerization inhibitors requiredissolved oxygen. Therefore, the monomer solution can be freed ofdissolved oxygen before the polymerization by inertization, i.e. flowingthrough with an inert gas, preferably nitrogen. The oxygen content ofthe monomer solution is preferably lowered before the polymerization toless than 1 ppm by weight, more preferably to less than 0.5 ppm byweight.

The solids content of the monomer solution is preferably at least 35% byweight, preferentially at least 38% by weight, more preferably at least40% by weight, most preferably at least 42% by weight. The solidscontent is the sum of all constituents which are involatile after thepolymerization.

The polymerization inhibitors can also be removed by absorption, forexample on activated carbon.

The monomer solution is metered into the gas phase to form droplets. Thedroplets can be generated, for example, by means of a dropletizer plate.

A dropletizer plate is a plate having at least one bore, the liquidentering the bore from the top. The dropletizer plate or the liquid canbe oscillated, which generates a chain of ideally monodisperse dropletsat each bore on the underside of the dropletizer plate. In a preferredembodiment, the dropletizer plate is not agitated.

The number and size of the bores are selected according to the desiredcapacity and droplet size. The droplet diameter is typically 1.9 timesthe diameter of the bore. What is important here is that the liquid tobe dropletized does not pass through the bore too rapidly and thepressure drop over the bore is not too great. Otherwise, the liquid isnot dropletized, but rather the liquid jet is broken up (sprayed) owingto the high kinetic energy. The Reynolds number based on the throughputper bore and the bore diameter is preferably less than 2000,preferentially less than 1000, more preferably less than 500 and mostpreferably less than 250.

The dropletizer plate has typically at least one bore, preferably atleast 10, more preferably at least 50 and typically up to 10 000 bores,preferably up to 5000, more preferably up to 1000 bores, the borestypically being distributed uniformly over the dropletizer plate,preferably in so-called triangular pitch, i.e. three bores in each caseform the corners of an equilateral triangle. The diameter of the boresis adjusted to the desired droplet size.

However, the droplets can also be generated by means of pneumaticdrawing dies, rotation, cutting of a jet or rapidly actuable microvalvedies.

In a pneumatic drawing die, a liquid jet together with a gas stream isaccelerated through a diaphragm. The gas rate can be used to influencethe diameter of the liquid jet and hence the droplet diameter.

In the case of droplet generation by rotation, the liquid passes throughthe orifices of a rotating disk. As a result of the centrifugal forceacting on the liquid, droplets of defined size are torn off. Preferredapparatus for rotary dropletization are described, for example, in DE 4308 842 A1.

The emerging liquid jet can also be cut into defined segments by meansof a rotating blade or an air-jet. Each segment then forms a droplet.

In the case of use of microvalve dies, droplets with defined liquidvolume are generated directly.

The droplets generated have a mean diameter of preferably at least 200μm, more preferably of at least 250 μm and most preferably of at least300 μm, the droplet diameter being determinable by means of lightscattering and meaning the volume-average mean diameter.

The mean diameter of the fluid-absorbent polymer particles obtainable bythe process is preferably at least 200 μm, more preferably from 250 to600 μm, very particularly from 300 to 500 μm, the particle diameterbeing determinable by light scattering and meaning the volume-averagemean diameter. 90% of the polymer particles have a diameter ofpreferably from 100 to 800 μm, more preferably from 150 to 700 μm andmost preferably from 200 to 600 μm.

The polymerization reactor is flowed through by a gas. The carrier gascan be conducted through the reaction chamber in concurrent or incountercurrent to the free-falling droplets of the monomer solution,preferably in concurrent, i.e. from the bottom upward. After one pass,the carrier gas is preferably recycled at least partly, preferably to anextent of at least 50%, more preferably to an extent of at least 75%,into the reaction chamber as cycle gas. Typically, a portion of thecarrier gas is discharged after each pass, preferably up to 10%, morepreferably up to 3% and most preferably up to 1%.

The gas velocity is preferably adjusted such that the flow in thepolymerization reactor is directed, for example no convection currentsopposed to the general flow direction are present, and is, for example,from 0.01 to 5 m/s, preferably from 0.02 to 4 m/s, more preferably from0.05 to 3 m/s, most preferably from 0.1 to 2 m/s.

The gas flowing through the reactor is appropriately preheated to thereaction temperature upstream of the reactor.

The gas entrance temperature, i.e. the temperature with which the gasenters the reaction chamber, is preferably from 160 to 250° C., morepreferably from 180 to 230° C., most preferably from 190 to 220° C.

Advantageously, the gas entrance temperature is controlled in such a waythat the gas exit temperature, i.e. the temperature with which the gasleaves the reaction chamber, is from 100 to 180° C., more preferablyfrom 110 to 160° C., most preferably from 120 to 140° C.

The reaction can be carried out under elevated pressure or under reducedpressure; preference is given to a reduced pressure of up to 100 mbarrelative to ambient pressure.

The reaction offgas, i.e. the gas leaving the reaction chamber, may, forexample, be cooled in a heat exchanger. This condenses water andunconverted monomer a). The reaction offgas can then be reheated atleast partly and recycled into the reactor as cycle gas. A portion ofthe reaction offgas can be discharged and replaced by fresh gas, inwhich case water and unconverted monomers a) present in the reactionoffgas can be removed and recycled.

Particular preference is given to a thermally integrated system, i.e. aportion of the waste heat in the cooling of the offgas is used to heatthe cycle gas.

The reactors can be trace-heated. In this case, the trace heating isadjusted such that the wall temperature is at least 5° C. above theinternal reactor temperature and condensation on the reactor walls isreliably prevented.

The fluid-absorbent polymer particles prepared by dropletizationpolymerization have a moisture content of preferably at least 10% byweight, more preferably at least 12% by weight, most preferably at least14% by weight. The moisture content can be adjusted by thepolymerization temperature and the residence time.

In a preferred embodiment of the present invention residual monomers inthe fluid-absorbent polymer particles obtained by dropletizationpolymerization are removed by a thermal aftertreatment in a fluidizedstate in the presence of a gas stream. The residual monomers can beremoved better at relatively high temperatures and relatively longresidence times. What is important here is that the fluid-absorbentpolymer particles are not too dry. In the case of excessively dryparticles, the residual monomers decrease only insignificantly. Too higha water content increases the caking tendency of the fluid-absorbentpolymer particles. In order that the fluid-absorbent polymer particlesdo not dry too rapidly during the thermal aftertreatment, the gasflowing in shall already comprise steam.

The polymer particles can subsequently be postcrosslinked for furtherimprovement of the properties.

Postcrosslinkers are compounds which comprise groups which can form atleast two covalent bonds with the carboxylate groups of the polymerparticles. Suitable compounds are, for example, polyfunctional amines,polyfunctional amidoamines, polyfunctional epoxides, as described in EP0 083 022 A2, EP 0 543 303 A1 and EP 0 937 736 A2, di- or polyfunctionalalcohols as described in DE 33 14 019 A1, DE 35 23 617 A1 and EP 0 450922 A2, or 3-hydroxyalkylamides, as described in DE 102 04 938 A1 andU.S. Pat. No. 6,239,230.

In addition, DE 40 20 780 C1 describes cyclic carbonates, DE 198 07 502A1 describes 2-oxazolidone and its derivatives such as2-hydroxyethyl-2-oxazolidone, DE 198 07 992 C1 describes bis- andpoly-2-oxazolidinones, DE 198 54 573 A1 describes2-oxotetrahydro-1,3-oxazine and its derivatives, DE 198 54 574 A1describes N-acyl-2-oxazolidones, DE 102 04 937 A1 describes cyclicureas, DE 103 34 584 A1 describes bicyclic amide acetals, EP 1 199 327A2 describes oxetanes and cyclic ureas, and WO 2003/31482 A1 describesmorpholine-2,3-dione and its derivatives, as suitable postcrosslinkers.

Particularly preferred postcrosslinkers are ethylene carbonate, mixturesof propylene glycol and 1,4-butanediol, ethylene glycol diglycidyl etherand reaction products of polyamides and epichlorohydrin.

Very particularly preferred postcrosslinkers are2-hydroxyethyl-2-oxazolidone, 2-oxazolidone and 1,3-propanediol.

In addition, it is also possible to use postcrosslinkers which compriseadditional polymerizable ethylenically unsaturated groups, as describedin DE 37 13 601 A1.

The amount of postcrosslinker is preferably from 0.001 to 2% by weight,more preferably from 0.02 to 1% by weight, most preferably from 0.05 to0.2% by weight, based in each case on the polymer.

In a preferred embodiment of the present invention, polyvalent cationsare applied to the particle surface in addition to the postcrosslinkersbefore, during or after the postcrosslinking.

The polyvalent cations usable in the process according to the inventionare, for example, divalent cations such as the cations of zinc,magnesium, calcium, iron and strontium, trivalent cations such as thecations of aluminum, iron, chromium, rare earths and manganese,tetravalent cations such as the cations of titanium and zirconium.Possible counterions are chloride, bromide, sulfate, hydrogensulfate,carbonate, hydrogencarbonate, nitrate, phosphate, hydrogenphosphate,dihydrogenphosphate and carboxylate, such as acetate and lactate.Aluminum sulfate is preferred. Apart from metal salts, it is alsopossible to use polyamines and/or polymeric amines as polyvalentcations.

The amount of polyvalent cation used is, for example, from 0.001 to 1.5%by weight, preferably from 0.005 to 1% by weight, more preferably from0.02 to 0.8% by weight, based in each case on the polymer.

The postcrosslinking is typically performed in such a way that asolution of the postcrosslinker is sprayed onto the hydrogel or the drypolymer particles. After the spraying, the polymer particles coated withthe postcrosslinker are dried thermally, and the postcrosslinkingreaction can take place either before or during the drying.

The spraying of a solution of the postcrosslinker is preferablyperformed in mixers with moving mixing tools, such as screw mixers, diskmixers, plowshare mixers and paddle mixers. Particular preference isgiven to horizontal mixers such as plowshare mixers and paddle mixers,very particular preference to vertical mixers. Suitable mixers are, forexample, Lödige mixers, Bepex mixers, Nauta mixers, Processall mixersand Schugl mixers. The postcrosslinker solution can also be sprayed intoa fluidized bed.

The postcrosslinkers are typically used as an aqueous solution. Theaddition of nonaqueous solvent can be used to adjust the penetrationdepth of the postcrosslinker into the polymer particles.

The thermal drying is preferably carried out in contact dryers, morepreferably paddle dryers, most preferably disk dryers. Suitable dryersare, for example, Bepex dryers and Nara dryers. Moreover, it is alsopossible to use fluidized bed dryers.

The drying can be effected in the mixer itself, by heating the jacket orblowing in warm air. Equally suitable is a downstream dryer, for examplea shelf dryer, a rotary tube oven or a heatable screw. It isparticularly advantageous to mix and dry in a fluidized bed dryer.

Preferred drying temperatures are in the range from 100 to 250° C.,preferably from 120 to 220° C., more preferably from 130 to 210° C.,most preferably from 150 to 200° C. The preferred residence time at thistemperature in the reaction mixer or dryer is preferably at least 10minutes, more preferably at least 20 minutes, most preferably at least30 minutes, and typically at most 60 minutes.

To further improve the properties, the postcrosslinked polymer particlescan be coated or subsequently moistened. Suitable coatings for improvingthe acquisition behavior and the saline flow conductivity (SFC) are, forexample, inorganic inert substances, such as water-insoluble metalsalts, organic polymers, cationic polymers and di- or polyvalent metalcations. Suitable coatings for dust binding are, for example, polyols.Suitable coatings against the undesired caking tendency of the polymerparticles are, for example, fumed silica, such as Aerosil® 200, andsurfactants, such as Span® 20.

C. Fluid-Absorbent Articles

The fluid-absorbent article comprises of

-   -   (A) an upper liquid-pervious layer    -   (B) a lower liquid-impervious layer    -   (C) a fluid-absorbent core between (A) and (B) comprising from 5        to 90% by weight a fibrous material and from 10 to 95% by weight        fluid-absorbent polymer particles;        -   preferably from 20 to 80% by weight a fibrous material and            from 20 to 80% by weight fluid-absorbent polymer particles;        -   more preferably from 30 to 75% by weight a fibrous material            and from 25 to 70% by weight fluid-absorbent polymer            particles;        -   most preferably from 40 to 70% by weight a fibrous material            and from 30 to 60% by weight fluid-absorbent polymer            particles;    -   (D) an optional acquisition-distribution layer between (A) and        (C), comprising from 80 to 100% by weight a fibrous material and        from 0 to 20% by weight fluid-absorbent polymer particles;        -   preferably from 85 to 99.9% by weight a fibrous material and            from 0.01 to 15% by weight fluid-absorbent polymer            particles;        -   more preferably from 90 to 99.5% by weight a fibrous            material and from 0.5 to 10% by weight fluid-absorbent            polymer particles;        -   most preferably from 95 to 99% by weight a fibrous material            and from 1 to 5% by weight fluid-absorbent polymer            particles;    -   (E) an optional tissue layer disposed immediately above and/or        below (C); and    -   (F) other optional components.

Fluid-absorbent articles are understood to mean, for example,incontinence pads and incontinence briefs for adults or diapers forbabies. Suitable fluid-absorbent articles including fluid-absorbentcompositions comprising fibrous materials and optionally fluid-absorbentpolymer particles to form fibrous webs or matrices for the substrates,layers, sheets and/or the fluid-absorbent core.

Suitable fluid-absorbent articles are composed of several layers whoseindividual elements must show preferably definite functional parametersuch as dryness for the upper liquid-pervious layer, vapor permeabilitywithout wetting through for the lower liquid-impervious layer, aflexible, vapor permeable and thin fluid-absorbent core, showing fastabsorption rates and being able to retain highest quantities of bodyfluids, and an acquisition-distribution layer between the upper layerand the core, acting as transport and distribution layer of thedischarged body fluids. These individual elements are combined such thatthe resultant fluid-absorbent article meets overall criteria such asflexibility, water vapour breathability, dryness, wearing comfort andprotection on the one side, and concerning liquid retention, rewet andprevention of wet through on the other side. The specific combination ofthese layers provides a fluid-absorbent article delivering both highprotection levels as well as high comfort to the consumer.

Liquid-Pervious Layer (A)

The liquid-pervious layer (A) is the layer which is in direct contactwith the skin. Thus, the liquid-pervious layer is preferably compliant,soft feeling and non-irritating to the consumer's skin. Generally, theterm “liquid-pervious” is understood thus permitting liquids, i.e. bodyfluids such as urine, menses and/or vaginal fluids to readily penetratethrough its thickness, The principle function of the liquid-perviouslayer is the acquisition and transport of body fluids from the wearertowards the fluid-absorbent core. Typically liquid-pervious layers areformed from any materials known in the art such as nonwoven material,films or combinations thereof. Suitable liquid-pervious layers (A)consist of customary synthetic or semisynthetic fibers or bicomponentfibers or films of polyester, polyolefins, rayon or natural fibers orany combinations thereof. In the case of nonwoven materials, the fibersshould generally be bound by binders such as polyacrylates. Additionallythe liquid-pervious layer may contain elastic compositions thus showingelastic characteristics allowing to be stretched in one or twodirections.

Suitable synthetic fibers are made from polyvinyl chloride, polyvinylfluoride, polytetrafluorethylene, polyvinylidene chloride, polyacrylics,polyvinyl acetate, polyethylvinyl acetate, non-soluble or solublepolyvinyl alcohol, polyolefins such as polyethylene, polypropylene,polyamides, polyesters, polyurethanes, polystyrenes and the like.

Examples for films are apertured formed thermoplastic films, aperturedplastic films, hydroformed thermoplastic films, reticulatedthermoplastic films, porous foams, reticulated foams, and thermoplasticscrims.

Examples of suitable modified or unmodified natural fibers includecotton, bagasse, kemp, flax, silk, wool, wood pulp, chemically modifiedwood pulp, jute, rayon, ethyl cellulose, and cellulose acetate.

Suitable wood pulp fibers can be obtained by chemical processes such asthe Kraft and sulfite processes, as well as from mechanical processes,such as ground wood, refiner mechanical, thermo-mechanical,chemi-mechanical and chemi-thermo-mechanical pulp processes. Further,recycled wood pulp fibers, bleached, unbleached, elementally chlorinefree (ECF) or total chlorine free (TCF) wood pulp fibers can be used.

The fibrous material may comprise only natural fibers or syntheticfibers or any combination thereof. Preferred materials are polyester,rayon and blends thereof, polyethylene, and polypropylene.

The fibrous material as a component of the fluid-absorbent compositionsmay be hydrophilic, hydrophobic or can be a combination of bothhydrophilic and hydrophobic fibers. The definition of hydrophilic isgiven in the section “definitions” in the chapter above. The selectionof the ratio hydrophilic/hydrophobic and accordingly the amount ofhydrophilic and hydrophobic fibers within fluid-absorbent compositionwill depend upon fluid handling properties and the amount offluid-absorbent polymer particles of the resulting fluid-absorbentcomposition. Such, the use of hydrophobic fibers is preferred if thefluid-absorbent composition is adjacent to the wearer of thefluid-absorbent article, that is to be used to replace partially orcompletely the upper liquid-pervious layer, preferably formed fromhydrophobic nonwoven materials. Hydrophobic fibers can also be member ofthe lower breathable, but fluid-impervious layer, acting there as afluid-impervious barrier.

Examples for hydrophilic fibers are cellulosic fibers, modifiedcellulosic fibers, rayon, polyester fibers such as polyethylenterephthalate, hydrophilic nylon and the like. Hydrophilic fibers canalso be obtained from hydrophobic fibers which are hydrophilized by e.g.surfactant-treating or silica-treating. Thus, hydrophilic thermoplasticfibers derived from polyolefins such as polypropylene, polyamides,polystyrenes or the like by surfactant-treating or silica-treating.

To increase the strength and the integrity of the upper-layer, thefibers should generally show bonding sites, which act as crosslinksbetween the fibers within the layer.

Technologies for consolidating fibers in a web are mechanical bonding,thermal bonding and chemical bonding, In the process of mechanicalbonding the fibers are entangled mechanically, e.g., by water jets(spunlace) to give integrity to the web. Thermal bonding is carried outby means of rising the temperature in the presence of low-meltingpolymers. Examples for thermal bonding processes are spunbonding,through-air bonding and resin bonding.

Preferred means of increasing the integrity are thermal bonding,spunbonding, resin bonding, through-air bonding and/or spunlace.

In the case of thermal bonding, thermoplastic material is added to thefibers. Upon thermal treatment at least a portion of this thermoplasticmaterial is melting and migrates to intersections of the fibers causedby capillary effects. These intersections solidify to bond sites aftercooling and increase the integrity of the fibrous matrix. Moreover, inthe case of chemically stiffened cellulosic fibers, melting andmigration of the thermoplastic material has the effect of increasing thepore size of the resultant fibrous layer while maintaining its densityand basis weight. Upon wetting, the structure and integrity of the layerremains stable. In summary, the addition of thermoplastic material leadsto improved fluid permeability of discharged body fluids and thus toimproved acquisition properties.

Suitable thermoplastic materials including polyolefins such aspolyethylene and polypropylene, polyesters, copolyesters, polyvinylacetate, polyethylvinyl acetate, polyvinyl chloride, polyvinylidenechloride, polyacrylics, polyamides, copolyamides, polystyrenes,polyurethanes and copolymers of any of the mentioned polymers.

Suitable thermoplastic fibers can be made from a single polymer that isa monocomponent fiber. Alternatively, they can be made from more thanone polymer, e.g., bi-component or multicomponent fibers. The term“bicomponent fibers” refers to thermoplastic fibers that comprise a corefiber made from a different fiber material than the shell. Typically,both fiber materials have different melting points, wherein generallythe sheath melts at lower temperatures. Bi-component fibers can beconcentric or eccentric depending whether the sheath has a thicknessthat is even or uneven through the cross-sectional area of thebi-component fiber. Advantage is given for eccentric bi-component fibersshowing a higher compressive strength at lower fiber thickness. Furtherbi-component fibers can show the feature “uncrimped” (unbent) or“crimped” (bent), further bi-component fibers can demonstrate differingaspects of surface lubricity.

Examples of bi-component fibers include the following polymercombinations: polyethylene/polypropylene, polyethylvinylacetate/polypropylene, polyethylene/polyester, polypropylene/polyester,copolyester/polyester and the like.

Suitable thermoplastic materials have a melting point of lowertemperatures that will damage the fibers of the layer; but not lowerthan temperatures, where usually the fluid-absorbent articles arestored. Preferably the melting point is between about 75° C. and 175° C.The typical length of thermoplastic fibers is from about 0.4 to 6 cm,preferably from about 0.5 to 1 cm. The diameter of thermoplastic fibersis defined in terms of either denier (grams per 9000 meters) or dtex(grams per 10 000 meters). Typical thermoplastic fibers have a dtex inthe range from about 1.2 to 20, preferably from about 1.4 to 10.

A further mean of increasing the integrity of the fluid-absorbentcomposition is the spunbonding technology. The nature of the productionof fibrous layers by means of spunbonding is based on the directspinning of polymeric granulates into continuous filaments andsubsequently manufacturing the fibrous layer.

Spunbond fabrics are produced by depositing extruded, spun fibers onto amoving belt in a uniform random manner followed by thermal bonding thefibers. The fibers are separated during the web laying process by airjets. Fiber bonds are generated by applying heated rolls or hot needlesto partially melt the polymer and fuse the fibers together. Sincemolecular orientation increases the melting point, fibers that are nothighly drawn can be used as thermal binding fibers. Polyethylene orrandom ethylene/propylene copolymers are used as low melting bondingsites.

Besides spunbonding, the technology of resin bonding also belongs tothermal bonding subjects. Using this technology to generate bondingsites, specific adhesives, based on e.g. epoxy, polyurethane and acrylicare added to the fibrous material and the resulting matrix isthermically treated. Thus the web is bonded with resin and/or thermalplastic resins dispersed within the fibrous material.

As a further thermal bonding technology through-air bonding involves theapplication of hot air to the surface of the fibrous fabric. The hot airis circulated just above the fibrous fabric, but does not push throughthe fibrous fabric. Bonding sites are generated by the addition ofbinders. Suitable binders used in through-air thermal bonding includecrystalline binder fibers, bi-component binder fibers, and powders. Whenusing crystalline binder fibers or powders, the binder melts entirelyand forms molten droplets throughout the nonwoven's cross-section.Bonding occurs at these points upon cooling. In the case of sheath/corebinder fibers, the sheath is the binder and the core is the carrierfiber. Products manufactured using through-air ovens tend to be bulky,open, soft, strong, extensible, breathable and absorbent. Through-airbonding followed by immediate cold calendering results in a thicknessbetween a hot roll calendered product and one that has been though-airbonded without compression. Even after cold calendering, this product issofter, more flexible and more extensible than area-bond hot-calenderedmaterial.

Spunlacing (“hydroentanglement”) is a further method of increasing theintegrity of a web. The formed web of loose fibers (usually air-laid orwet-laid) is first compacted and prewetted to eliminate air pockets. Thetechnology of spunlacing uses multiple rows of fine high-speed jets ofwater to strike the web on a porous belt or moving perforated orpatterned screen so that the fibers knot about one another. The waterpressure generally increases from the first to the last injectors.Pressures as high as 150 bar are used to direct the water jets onto theweb. This pressure is sufficient for most of the nonwoven fibers,although higher pressures are used in specialized applications.

The spunlace process is a nonwovens manufacturing system that employsjets of water to entangle fibers and thereby provide fabric integrity.Softness, drape, conformability, and relatively high strength are themajor characteristics of spunlace nonwoven.

In newest researches benefits are found in some structural features ofthe resulting liquid-pervious layers. For example, the thickness of thelayer is very important and influences together with its x-y dimensionthe acquisition-distribution behaviour of the layer. If there is furthersome profiled structure integrated, the acquisition-distributionbehaviour can be directed depending on the three-dimensional structureof the layer. Thus 3D-polyethylene in the function of liquid-perviouslayer is preferred.

Thus, suitable liquid-pervious layers (A) are nonwoven layers formedfrom the fibers above by thermal bonding, spunbonding, resin bonding orthrough-air bonding. Further suitable liquid-pervious layers are3D-polyethylene layers and spunlace.

Preferably the 3D-polyethylene layers and spunlace show basis weightsfrom 12 to 22 gsm.

Typically liquid-pervious layers (A) extend partially or wholly acrossthe fluid-absorbent structure and can extend into and/or form part ofall the preferred sideflaps, side wrapping elements, wings and ears.

Liquid-Impervious Layer (B)

The liquid-impervious layer (B) prevents the exudates absorbed andretained by the fluid-absorbent core from wetting articles which are incontact with the fluid-absorbent article, as for example bedsheets,pants, pajamas and undergarments. The liquid-impervious layer (B) maythus comprise a woven or a nonwoven material, polymeric films such asthermoplastic film of polyethylene or polypropylene, or compositematerials such as film-coated nonwoven material.

Suitable liquid-impervious layers include nonwoven, plastics and/orlaminates of plastic and nonwoven. Both, the plastics and/or laminatesof plastic and nonwoven may appropriately be breathable, that is, theliquid-impervious layer (B) can permit vapors to escape from thefluid-absorbent material. Thus the liquid-impervious layer has to have adefinite water vapor transmission rate and at the same time the level ofimpermeability. To combine these features, suitable liquid-imperviouslayers including at least two layers, e.g. laminates from fibrousnonwoven having a specified basis weight and pore size, and a continuousthree-dimensional film of e.g. polyvinylalcohol as the second layerhaving a specified thickness and optionally having pore structure. Suchlaminates acting as a barrier and showing no liquid transport or wetthrough. Thus, suitable liquid-impervious layers comprising at least afirst breathable layer of a porous web which is a fibrous nonwoven, e.g.a composite web of a meltblown nonwoven layer or of a spunbondednonwoven layer made from synthetic fibers and at least a second layer ofa resilient three dimensional web consisting of a liquid-imperviouspolymeric film, e.g. plastics optionally having pores acting ascapillaries, which are preferably not perpendicular to the plane of thefilm but are disposed at an angle of less than 90° relative to the planeof the film.

Suitable liquid-impervious layers are permeable for vapor. Preferablythe liquid-impervious layer is constructed from vapor permeable materialshowing a water vapor transmission rate (WVTR) of at least about 100 gsmper 24 hours, preferably at least about 250 gsm per 24 hours and mostpreferred at least about 500 gsm per 24 hours.

Preferably the liquid-impervious layer (B) is made of nonwovencomprising hydrophobic materials, e.g. synthetic fibers or aliquid-impervious polymeric film comprising plastics e.g. polyethylene.The thickness of the liquid-impervious layer is preferably 15 to 30 μm.

Further, the liquid-impervious layer (B) is preferably made of alaminate of nonwoven and plastics comprising a nonwoven having a densityof 12 to 15 gsm and a polyethylene layer having a thickness of about 10to 20 μm.

The typically liquid-impervious layer (B) extends partially or whollyacross the fluid-absorbent structure and can extend into and/or formpart of all the preferred sideflaps, side wrapping elements, wings andears.

Fluid-Absorbent Core (C)

The fluid-absorbent core (C) is disposed between the upperliquid-pervious layer (A) and the lower liquid-impervious layer (B).Suitable fluid-absorbent cores (C) may be selected from any of thefluid-absorbent core-systems known in the art provided that requirementssuch as vapor permeability, flexibility and thickness are met. Suitablefluid-absorbent cores refer to any fluid-absorbent composition whoseprimary function is to acquire, transport, distribute, absorb, store andretain discharged body fluids.

The top view area of the fluid-absorbent core (C) is preferably at least200 cm², more preferably at least 2550 cm², most preferably at least 300cm². The top view area is the part of the core that is face-to-face tothe upper liquid-pervious layer.

According to the present invention the fluid-absorbent core can includethe following components:

-   -   1. an optional core cover    -   2. a fluid storage layer    -   3. an optional dusting layer

1. Optional Core Cover

In order to increase the integrity of the fluid-absorbent core, the coreis provided with a cover. This cover may be at the top and/or at thebottom of the fluid-absorbent core. Further, this cover may include thewhole fluid-absorbent core with a unitary sheet of material and thusfunction as a wrap. Wrapping is possible as a full wrap, a partial wrapor as a C-Wrap.

The material of the core cover may comprise any known type of substrate,including webs, garments, textiles, films, tissues and laminates of twoor more substrates or webs. The core cover material may comprise naturalfibers, such as cellulose, cotton, flax, linen, hemp, wool, silk, fur,hair and naturally occurring mineral fibers. The core cover material mayalso comprise synthetic fibers such as rayon and lyocell (derived fromcellulose), polysaccharides (starch), polyolefin fibers (polypropylene,polyethylene), polyamides, polyester, butadiene-styrene blockcopolymers, polyurethane and combinations thereof. Preferably, the corecover comprises synthetic fibers or tissue.

The fibers may be mono- or multicomponent. Multicomponent fibers maycomprise a homopolymer, a copolymer or blends thereof.

2. Fluid-Storage Layer

The fluid-absorbent compositions included in the fluid-absorbent corecomprise fibrous materials and fluid-absorbent polymer particles.

Fibers useful in the present invention include natural fibers andsynthetic fibers. Examples of suitable modified or unmodified naturalfibers are given in the chapter “Liquid-pervious Layer (A)” above. Fromthose, wood pulp fibers are preferred.

Examples of suitable synthetic fibers are given in the chapter“Liquid-pervious Layer (A)” above. The fibrous material may compriseonly natural fibers or synthetic fibers or any combination thereof.

The fibrous material as a component of the fluid-absorbent compositionsmay be hydrophilic, hydrophobic or can be a combination of bothhydrophilic and hydrophobic fibers.

Generally for the use in a fluid-absorbent core, which is the embeddedbetween the upper layer (A) and the lower layer (B), hydrophilic fibersare preferred. This is especially the case for fluid-absorbentcompositions that are desired to quickly acquire, transfer anddistribute discharged body fluids to other regions of thefluid-absorbent composition or fluid-absorbent core. The use ofhydrophilic fibers is especially preferred for fluid-absorbentcompositions comprising fluid-absorbent polymer particles.

Examples for hydrophilic fibers are given in the chapter“Liquid-pervious Layer (A)” above. Preferably, the fluid-absorbent coreis made from viscose acetate, polyester and/or polypropylene.

The fibrous material of the fluid-absorbent core may be uniformly mixedto generate a homogenous or inhomogenous fluid-absorbent core.Alternatively the fibrous material may be concentrated or laid inseparate layers optionally comprising fluid-absorbent polymer material.Suitable storage layers of the fluid-absorbent core comprisinghomogenous mixtures of fibrous materials comprising fluid-absorbentpolymer material. Suitable storage layers of the fluid-absorbent coreincluding a layered core-system comprise homogenous mixtures of fibrousmaterials and comprise fluid-absorbent polymer material, whereby each ofthe layers may be built from any fibrous material by means known in theart. The sequence of the layers may be directed such that a desiredfluid acquisition, distribution and transfer results, depending on theamount and distribution of the inserted fluid-absorbent material, e.g.fluid-absorbent polymer particles. Preferably there are discrete zonesof highest absorption rate or retention within the storage layer of thefluid-absorbent core, formed of layers or inhomogenous mixtures of thefibrous material, acting as a matrix for the incorporation offluid-absorbent polymer particles. The zones may extend over the fullarea or may form only parts of the fluid-absorbent core.

Suitable fluid-absorbent cores comprise fibrous material andfluid-absorbent material. Suitable is any fluid-absorbent material thatis capable of absorbing and retaining body fluids or body exudates suchas cellulose wadding, modified and unmodified cellulose, crosslinkedcellulose, laminates, composites, fluid-absorbent foams, materialsdescribed as in the chapter “Liquid-pervious Layer (A)” above,fluid-absorbent polymer particles and combinations thereof.

Typically the fluid-absorbent cores may contain a single type offluid-absorbent polymer particles or may contain fluid-absorbent polymerparticles derived from different kinds of fluid-absorbent polymermaterial. Thus, it is possible to add fluid-absorbent polymer particlesfrom a single kind of polymer material or a mixture of fluid-absorbentpolymer particles from different kinds of polymer materials, e.g. amixture of regular fluid-absorbent polymer particles, derived from gelpolymerization with fluid-absorbent polymer particles, derived fromdropletization polymerization. Alternatively it is possible to addfluid-absorbent polymer particles derived from inverse suspensionpolymerization.

Alternatively it is possible to mix fluid-absorbent polymer particlesshowing different feature profiles. Thus, the fluid-absorbent core maycontain fluid-absorbent polymer particles with uniform pH value, or itmay contain fluid-absorbent polymer particles with different pH values,e.g. two- or more component mixtures from fluid-absorbent polymerparticles with a pH in the range from about 4.0 to about 7.0.Preferably, applied mixtures deriving from mixtures of fluid-absorbentpolymer particles got from gel polymerization or inverse suspensionpolymerization with a pH in the range from about 4.0 to about 7.0 andfluid-absorbent polymer particles got from drop polymerization.

Suitable fluid-absorbent cores are also manufactured from loose fibrousmaterials by adding fluid-absorbent particles and/or fluid-absorbentpolymer fibers or mixtures thereof. The fluid-absorbent polymer fibersmay be formed from a single type of fluid-absorbent polymer fiber or maycontain fluid-absorbent polymer fibers from different polymericmaterials. The addition of fluid-absorbent polymer fibers may bepreferred for being distributed and incorporated easily into the fibrousstructure and remaining better in place than fluid-absorbent polymerparticles. Thus, the tendency of gel blocking caused by contacting eachother is reduced. Further, fluid-absorbent polymer fibers are softer andmore flexible.

In the process of manufacturing the fluid-absorbent core,fluid-absorbent polymer particles and/or fluid-absorbent fibers arebrought together with structure forming compounds such as fibrousmatrices. Thus, the fluid-absorbent polymer particles and/orfluid-absorbent fibers may be added during the process of forming thefluid-absorbent core from loose fibers. The fluid-absorbent core may beformed by mixing fluid-absorbent polymer particles and/orfluid-absorbent fibers with fibrous materials of the matrix at the sametime or adding one component to the mixture of two or more othercomponents either at the same time or by continuously adding.

Suitable fluid-absorbent cores including mixtures of fluid-absorbentpolymer particles and/or fluid-absorbent fibers and fibrous materialbuilding matrices for the incorporation of the fluid-absorbent material.Such mixtures can be formed homogenously, that is all components aremixed together to get a homogenous structure. The amount of thefluid-absorbent materials may be uniform throughout the fluid-absorbentcore, or may vary, e.g. between the central region and the distal regionto give a profiled core concerning the concentration of fluid-absorbentmaterial.

Techniques of application of the fluid-absorbent polymer materials intothe absorbent core are known to persons skilled in the art and may bevolumetric, loss-in-weight or gravimetric. Known techniques include theapplication by vibrating systems, single and multiple auger systems,dosing roll, weigh belt, fluid bed volumetric systems and gravitationalsprinkle and/or spray systems. Further techniques of insertion arefalling dosage systems consensus and contradictory pneumatic applicationor vacuum printing method of applying the fluid absorbent polymermaterials.

Suitable fluid-absorbent cores may also include layers, which are formedby the process of manufacturing the fluid-absorbent article. The layeredstructure may be formed by subsequently generating the different layersin z-direction.

Alternatively a core-structure can be formed from two or more preformedlayers to get a layered fluid-absorbent core. The layers may havedifferent concentrations of fluid-absorbent polymer material showingconcentrations in the range from about 10 to 95%. These uniform ordifferent layers can be fixed to each other at their adjacent planesurfaces. Alternatively, the layers may be combined in a way that aplurality of chambers are formed, in which separately fluid-absorbentpolymer material is incorporated.

Suitable preformed layers are processed as e.g. air-laid, wet-laid,laminate or composite structure.

Alternatively layers of other materials can be added, e.g. layers ofopened or closed celled foams or perforated films. Included are alsolaminates of at least two layers comprising said fluid-absorbent polymermaterial.

Further a composite structure can be formed from a carrier layer (e.g. apolymer film), onto which the fluid-absorbent polymer material isaffixed. The fixation can be done at one side or at both sides. Thecarrier layer may be pervious or impervious for body-fluids.

Alternatively, it is possible to add monomer solution after theformation of a layer or onto a carrier layer and polymerize the coatingsolution by means of UV-induced polymerization technologies. Thus, “insitu”-polymerization is a further method for the application offluid-absorbent polymers.

Thus, suitable fluid-absorbent cores comprising from 5 to 90% by weighta fibrous material and from 10 to 95% by weight fluid-absorbent polymerparticles; preferably from 20 to 80% by weight a fibrous material andfrom 20 to 80% by weight fluid-absorbent polymer particles; morepreferably from 30 to 75% by weight a fibrous material and from 25 to70% by weight fluid-absorbent polymer particles and most preferably from40 to 70% by weight a fibrous material and from 30 to 60% by weightfluid-absorbent polymer particles.

The quantity of fluid-absorbent polymer particles and/or fluid-absorbentfibers within the fluid-absorbent core is from 3 to 20 g, preferablyfrom 6 to 14 g, and from 8 to 12 g in the case of maxi-diapers, and inthe case of incontinence products up to about 50 g.

Typically fluid-absorbent articles comprising at least an upperliquid-pervious layer (A), at least a lower liquid-impervious layer (B)and at least one fluid-absorbent core between the layer (A) and thelayer (B) besides other optional layers. In order to increase thecontrol of body fluid absorption and/or to increase the flexibility inthe ratio weight percentages of fluid-absorbent polymer particles tofibrous matrix it may be advantageous to add one or more furtherfluid-absorbent cores. The addition of a second fluid-absorbent core tothe first fluid-absorbent core offers more possibilities in body fluidtransfer and distribution. Moreover higher quantities of discharged bodyfluids can be retained. Having the opportunity of combining severallayers showing different fluid-absorbent polymer concentration andcontent, it is possible to reduce the thickness of the fluid-absorbentarticle to a minimum even if there are several fluid-absorbent coresincluded.

Suitable fluid-absorbent cores may be formed from any material known inthe art which is designed to acquire, transfer, and retain dischargedbody fluids. The technology of manufacturing may also be anyone known inthe art. Preferred technologies include the application ofmonomer-solution to a transported fibrous matrix and therebypolymerizing, known as in-situ technology, or the manufacturing ofair-laid composites.

Suitable fluid-absorbent articles are including single or multi-coresystems in any combination with other layers which are typically foundin fluid-absorbent articles. Preferred fluid-absorbent articles includesingle- or double-core systems; most preferably fluid-absorbent articlesinclude a single fluid-absorbent core.

The fluid-absorbent core typically has a uniform size or profile.Suitable fluid-absorbent cores can also have profiled structures,concerning the shape of the core and/or the content of fluid-absorbentpolymer particles and/or the distribution of the fluid-absorbent polymerparticles and/or the dimensions of the different layers if a layeredfluid-absorbent core is present.

It is known that absorbent cores providing a good wet immobilization bycombining several layers, e.g. a substrate layer, layers offluid-absorbent polymer and layers of thermoplastic material. Suitableabsorbent cores may also comprise tissue or tissue laminates. Known inthe art are single or double layer tissue laminates formed by foldingthe tissue or the tissue laminate onto itself.

These layers or foldings are preferably joined to each e.g. by additionof adhesives or by mechanical, thermal or ultrasonic bonding orcombinations thereof. Fluid-absorbent polymer particles may be comprisedwithin or between the individual layers, e.g. by forming separatefluid-absorbent polymer-layers.

Thus, according to the number of layers or the height of a voluminouscore, the resulting thickness of the fluid-absorbent core will bedetermined. Thus, fluid-absorbent cores may be flat as one layer(plateau) or have three-dimensional profile.

Generally the upper liquid-pervious layer (A) and the lowerliquid-impervious layer (B) may be shaped and sized according to therequirements of the various types of fluid-absorbent articles and toaccommodate various wearer's sizes. Thus, the combination of the upperliquid-pervious layer and the lower liquid-impervious layer may have alldimensions or shapes known in the art. Suitable combinations have anhourglass shape, rectangular shape, trapezoidal shape, t- or doublet-shape or showing anatomical dimensions.

The fluid-absorbent core may comprise additional additives typicallypresent in fluid-absorbent articles known in the art. Exemplaryadditives are fibers for reinforcing and stabilizing the fluid-absorbentcore. Preferably polyethylene is used for reinforcing thefluid-absorbent core.

Further suitable stabilizer for reinforcing the fluid-absorbent core arematerials acting as binder.

In varying the kind of binder material or the amount of binder used indifferent regions of the fluid-absorbent core it is possible to get aprofiled stabilization. For example, different binder materialsexhibiting different melting temperatures may be used in regions of thefluid-absorbent core, e.g. the lower melting one in the central regionof the core, and the higher melting in the distal regions. Suitablebinder materials may be adhesive or non-adhesive fibers, continuously ordiscontinuously extruded fibers, bi-component staple fibers,nonelastomeric fibers and sprayed liquid binder or any combination ofthese binder materials.

Further, thermoplastic compositions usually are added to increase theintegrity of the core layer. Thermoplastic compositions may comprise asingle type of thermoplastic polymers or a blend of thermoplasticpolymers. Alternatively, the thermoplastic composition may comprise hotmelt adhesives comprising at least one thermoplastic polymer togetherwith thermoplastic diluents such as tackifiers, plasticizers or otheradditives, e.g. antioxidants. The thermoplastic composition may furthercomprise pressure sensitive hot melt adhesives comprising e.g.crystalline polypropylene and an amorphous polyalphaolefin or styreneblock copolymer and mixture of waxes.

Suitable thermoplastic polymers are styrenic block copolymers includingA-B-A triblock segments, A-B diblock segments and (A-B), radial blockcopolymer segments. The letter A designs non-elastomeric polymersegments, e.g. polystyrene, and B stands for unsaturated conjugateddiene or their (partly) hydrogenated form. Preferably B comprisesisoprene, butadiene, ethylene/butylene (hydrogenated butadiene),ethylene/propylene (hydrogenated isoprene) and mixtures thereof.

Other suitable thermoplastic polymers are amorphous polyolefins,amorphous polyalphaolefins and metallocene polyolefins.

Concerning odor control, perfumes and/or odor control additives areoptionally added. Suitable odor control additives are all substances ofreducing odor developed in carrying fluid-absorbent articles over timeknown in the art. Thus, suitable odor control additives are inorganicmaterials, such as zeolites, activated carbon, bentonite, silica,aerosile, kieselguhr, clay; chelants such as ethylenediamine tetraaceticacid (EDTA), cyclodextrins, aminopolycarbonic acids, ethylenediaminetetramethylene phosphonic acid, aminophosphate, polyfunctional aromates,N,N-disuccinic acid.

Suitable odor control additives are further antimicrobial agents such asquaternary ammonium, phenolic, amide and nitro compounds and mixturesthereof; bactericides such as silver salts, zinc salts, cetylpyridiniumchloride and/or triclosan as well as surfactants having an HLB value ofless than 12.

Suitable odor control additives are further compounds with anhydridegroups such as maleic-, itaconic-, polymaleic- or polyitaconicanhydride, copolymers of maleic acid with C₂-C₈ olefins or styrene,polymaleic anhydride or copolymers of maleic anhydride with isobutene,di-isobutene or styrene, compounds with acid groups such as ascorbic,benzoic, citric, salicylic or sorbic acid and fluid-soluble polymers ofmonomers with acid groups, homo- or co-polymers of C₃-C₅mono-unsaturated carboxylic acids.

Suitable odor control additives are further perfumes such as allylcaproate, allyl cyclohexaneacetate, allyl cyclohexanepropionate, allylheptanoate, amyl acetate, amyl propionate, anethol, anixic aldehyde,anisole, benzaldehyde, benzyl acetete, benzyl acetone, benzyl alcohol,benzyl butyrate, benzyl formate, camphene, camphor gum, laevo-carveol,cinnamyl formate, cis-jasmone, citral, citronellol and its derivatives,cuminic alcohol and its derivatives, cyclal C, dimethyl benzyl carbinoland its derivatives, dimethyl octanol and its derivatives, eucalyptol,geranyl derivatives, lavandulyl acetete, ligustral, d-limonene,linalool, linalyl derivatives, menthone and its derivatives, myrcene andits derivatives, neral, nerol, p-cresol, p-cymene, orange terpenes,alphaponene, 4-terpineol, thymol etc.

Masking agents are also used as odor control additives. Masking agentsare in solid wail material encapsulated perfumes. Preferably, the wallmaterial comprises a fluid-soluble cellular matrix which is used fortime-delay release of the perfume ingredient.

Further suitable odor control additives are transition metals such asCu, Ag, Zn; enzymes such as urease-inhibitors, starch, pH bufferingmaterial, chitin, green tea plant extracts, ion exchange resin,carbonate, bicarbonate, phosphate, sulfate or mixtures thereof.

Preferred odor control additives are green tea plant extracts, silica,zeolite, carbon, starch, chelating agent, pH buffering material, chitin,kieselguhr, clay, ion exchange resin, carbonate, bicarbonate, phosphate,sulfate, masking agent or mixtures thereof. Suitable concentrations ofodor control additives are from about 0.5 to about 300 gsm.

Newest developments propose the addition of wetness indicationadditives. Besides electrical monitoring the wetness in thefluid-absorbent article, wetness indication additives comprising a hotmelt adhesive with a wetness indicator are known. The wetness indicationadditive changes the colour from yellow to a relatively dark and deepblue. This colour change is readily perceivable through theliquid-impervious outer material of the fluid-absorbent article.Existing wetness indication is also achieved via application of watersoluble ink patterned on the backsheet which disappears when wet.

Suitable wetness indication additives comprising a mixture of sorbitanmonooleate and polyethoxylated hydrogenated castor oil. Preferably, theamount of the wetness indication additive is in the range of about 1 to5% by weight related to the weight of the fluid-absorbent core.

The basis weight of the fluid-absorbent core is in the range of 600 to1200 gsm. The density of the fluid-absorbent core is in the range of 0.1to 0.25 g/cm³. The thickness of the fluid-absorbent core is in the caseof diapers in the range of 1 to 5 mm, preferably 1.5 to 3 mm, in thecase of incontinence products in the range of 3 to 15 mm.

3. Optional Dusting Layer

An optional component for inclusion into the absorbent core is a dustinglayer adjacent to. The dusting layer is a fibrous layer and may beplaced on the top and/or the bottom of the absorbent core. Typically,the dusting layer is underlying the storage layer. This underlying layeris referred to as a dusting layer, since it serves as carrier fordeposited fluid-absorbent polymer particles during the manufacturingprocess of the fluid-absorbent core. If the fluid-absorbent polymermaterial is in the form of microstructures, films or flakes, theinsertion of a dusting layer is not necessary. In the case offluid-absorbent polymer particles derived from dropletizationpolymerization, the particles have a smooth surface with no edges. Alsoin this case, the addition of a dusting layer to the fluid-absorbentcore is not necessary. On the other side, as a great advantage thedusting layer provides some additional fluid-handling properties such aswicking performance and may offer reduced incidence of pin-holing and orpock marking of the liquid impervious layer (B).

Preferably, the dusting layer is a fibrous layer comprising fluff(cellulose fibers).

Optional Acquisition-Distribution Layer (D)

An optional acquisition-distribution layer (D) is located between theupper layer (A) and the fluid-absorbent core (C) and is preferablyconstructed to efficiently acquire discharged body fluids and totransfer and distribute them to other regions of the fluid-absorbentcomposition or to other layers, where the body fluids are immobilizedand stored. Thus, the upper layer transfers the discharged liquid to theacquisition-distribution layer (D) for distributing it to thefluid-absorbent core.

The acquisition-distribution layer comprises fibrous material andoptionally fluid-absorbent polymer particles.

The fibrous material may be hydrophilic, hydrophobic or can be acombination of both hydrophilic and hydrophobic fibers. It may bederived from natural fibers, synthetic fibers or a combination of both.

Suitable acquisition-distribution layers are formed from cellulosicfibers and/or modified cellulosic fibers and/or synthetics orcombinations thereof. Thus, suitable acquisition-distribution layers maycontain cellulosic fibers, in particular wood pulp fluff. Examples offurther suitable hydrophilic, hydrophobic fibers, as well as modified orunmodified natural fibers are given in the chapter “Liquid-perviousLayer (A)” above.

Especially for providing both fluid acquisition and distributionproperties, the use of modified cellulosic fibers is preferred. Examplesfor modified cellulosic fibers are chemically treated cellulosic fibers,especially chemically stiffened cellulosic fibers. The term “chemicallystiffened cellulosic fibers” means cellulosic fibers that have beenstiffened by chemical means to increase the stiffness of the fibers.Such means include the addition of chemical stiffening agent in the formof coatings and impregnates. Suitable polymeric stiffening agents caninclude: cationic modified starches having nitrogen-containing groups,latexes, wet strength resins such as polyamide-epichlorohydrin resin,polyacrylamide, urea formaldehyde and melamine formaldehyde resins andpolyethylenimine resins.

Stiffening may also include altering the chemical structure, e.g. bycrosslinking polymer chains. Thus crosslinking agents can be applied tothe fibers that are caused to chemically form intrafiber crosslinkbonds. Further cellulosic fibers may be stiffened by crosslink bonds inindividualized form. Suitable chemical stiffening agents are typicallymonomeric crosslinking agents including C₂-C₈ dialdehyde, C₂-C₈monoaldehyde having an acid functionality, and especially C₂-C₈polycarboxylic acids.

Preferably the modified cellulosic fibers are chemically treatedcellulosic fibers. Especially preferred are curly fibers which can beobtained by treating cellulosic fibers with citric acid. Preferably thebasis weight of cellulosic fibers and modified cellulosic fibers is from50 to 200 gsm.

Suitable acquisition-distribution layers further include syntheticalfibers. Known examples of synthetical fibers are found in the Chapter“Liquid-pervious Layer (A)” above. 3D-polyethylene in the function ofacquisition-distribution layer is preferred.

Further, as in the case of cellulosic fibers, hydrophilic syntheticalfibers are preferred. Hydrophilic synthetical fibers may be obtained bychemical modification of hydrophobic fibers. Preferably,hydrophilization is carried out by surfactant treatment of hydrophobicfibers. Thus the surface of the hydrophobic fiber can be renderedhydrophilic by treatment with a nonionic or ionic surfactant, e.g., byspraying the fiber with a surfactant or by dipping the fiber into asurfactant. Further preferred are permanent hydrophilic syntheticfibers.

The fibrous material of the acquisition-distribution layer may be fixedto increase the strength and the integrity of the layer. Technologiesfor consolidating fibers in a web are mechanical bonding, thermalbonding and chemical bonding. Detailed description of the differentmethods of increasing the integrity of the web is given in the Chapter“Liquid-pervious Layer (A)” above.

Preferred acquisition-distribution layers comprise fibrous material andfluid-absorbent polymer particles distributed within. Thefluid-absorbent polymer particles may be added during the process offorming the layer from loose fibers, or, alternatively, it is possibleto add monomer solution after the formation of the layer and polymerizethe coating solution by means of UV-induced polymerisation technologies.Thus, “in situ”-polymerisation is a further method for the applicationof fluid-absorbent polymers.

Thus, suitable acquisition-distribution layers comprising from 80 to100% by weight a fibrous material and from 0 to 20% by weightfluid-absorbent polymer particles; preferably from 85 to 99.9% by weighta fibrous material and from 0.1 to 15% by weight fluid-absorbent polymerparticles; more preferably from 90 to 99.5% by weight a fibrous materialand from 0.5 to 10% by weight fluid-absorbent polymer particles; andmost preferably from 95 to 99% by weight a fibrous material and from 1to 5% by weight fluid-absorbent polymer particles.

Preferred acquisition-distribution layers show basis weights in therange from 20 to 200 gsm, most preferred in the range from 40 to 50 gsm,depending on the concentration of fluid-absorbent polymer particles.

Optional Tissue Layer (E)

An optional tissue layer is disposed immediately above and/or below (C).

The material of the tissue layer may comprise any known type ofsubstrate, including webs, garments, textiles and films. The tissuelayer may comprise natural fibers, such as cellulose, cotton, flax,linen, hemp, wool, silk, fur, hair and naturally occurring mineralfibers. The tissue layer may also comprise synthetic fibers such asrayon and lyocell (derived from cellulose), polysaccharides (starch),polyolefin fibers (polypropylene, polyethylene), polyamides, polyester,butadiene-styrene block copolymers, polyurethane and combinationsthereof. Preferably, the tissue layer comprises cellulose fibers.

Other Optional Components (F) 1. Leg Cuff

Typical leg cuffs comprising nonwoven materials which can be formed bydirect extrusion processes during which the fibers and the nonwovenmaterials are formed at the same time, or by laying processes ofpreformed fibers which can be laid into nonwoven materials at a laterpoint of time. Examples for direct extrusion processes includespunbonding, meltblowing, solvent spinning, electrospinning andcombinations thereof. Examples of laying processes include wet-layingand dry-laying (e.g. air-laying, carding) methods. Combinations of theprocesses above include spunbond-meltblown-spunbond (sms),spunbond-meltblow-meltblown-spunbond (smms), spunbond-carded (sc),spunbond-airlaid (sa), meltblown-airlaid (ma) and combinations thereof.The combinations including direct extrusion can be combined at the samepoint in time or at a subsequent point in time. In the examples above,one or more individual layers can be produced by each process. Thus,“sms” means a three layer nonwoven material, “smsms” or “ssmms” means afive layer nonwoven material. Usually, small type letters (sms)designate individual layers, whereas capital letters (SMS) designate thecompilation of similar adjacent layers.

Further, suitable leg cuffs are provided with elastic strands.

Preferred are leg cuffs from synthetic fibers showing the layercombinations sms, smms or smsms. Preferred are nonwovens with thedensity of 13 to 17 gsm. Preferably leg cuffs are provided with twoelastic strands.

2. Elastics

The elastics are used for securely holding and flexibly closing thefluid-absorbent article around the wearers body, e.g. the waist and thelegs to improve containment and fit. Leg elastics are placed between theouter and inner layers or the fluid-absorbent article, or between theouter cover and the bodyside liner. Suitable elastics comprising sheets,ribbons or strands of thermoplastic polyurethane, elastomeric materials,poly(ether-amide) block copolymers, thermoplastic rubbers,styrene-butadiene copolymers, silicon rubbers, natural rubbers,synthetic rubbers, styrene isoprene copolymers, styrene ethylenebutylene copolymers, nylon copolymers, spandex fibers comprisingsegmented polyurethane and/or ethylene-vinyl acetate copolymer. Theelastics may be secured to a substrate after being stretched, or securedto a stretched substrate. Otherwise, the elastics may be secured to asubstrate and then elasticized or shrunk, e.g. by the application ofheat.

3. Closing System

The closing system include tape tabs, landing zone, elastomerics, pullups and the belt system.

At least a part of the first waist region is attached to a part of thesecond waist region by the closing system to hold the fluid-absorbentarticle in place and to form leg openings and the waist of thefluid-absorbent article. Preferably the fluid-absorbent article isprovided with a re-closable closing system.

The closing system is either re-sealable or permanent, including anymaterial suitable for such a use, e.g. plastics, elastics, films, foams,nonwoven substrates, woven substrates, paper, tissue, laminates, fiberreinforced plastics and the like, or combinations thereof. Preferablythe closing system includes flexible materials and works smooth andsoftly without irritating the wearer's skin.

One part of the closing elements is an adhesive tape, or comprises apair of laterally extending tabs disposed on the lateral edges of thefirst waist region. Tape tabs are typically attached to the front bodypanel and extend laterally from each corner of the first waistband.These tape tabs include an adhesive inwardly facing surface which istypically protected prior to use by a thin, removable cover sheet.

Suitable tape tabs may be formed of thermoplastic polymers such aspolyethylene, polyurethane, polystyrene, polycarbonate, polyester,ethylene vinyl acetate, ethylene vinyl alcohol, ethylene vinyl acetateacrylate or ethylene acrylic acid copolymers.

Suitable closing systems comprise further a hook portion of a hook andloop fastener and the target devices comprise the loop portion of a hookand loop fastener.

Suitable mechanical closing systems including a landing zone. Mechanicalclosing systems may fasten directly into the outer cover. The landingzone may act as an area of the fluid-absorbent article into which it isdesirable to engage the tape tabs. The landing zone may include a basematerial and a plurality of tape tabs. The tape tabs may be embedded inthe base material of the landing zone. The base material may include aloop material. The loop material may include a backing material and alayer of a nonwoven spunbond web attacked to the backing material.

Thus suitable landing zones can be made by spunbonding. Spunbondednonwoven are made from melt-spun fibers formed by extruding moltenthermoplastic material. Preferred is bioriented polypropylene (BOPP), orbrushed/closed loop in the case of mechanical closing systems.

Further, suitable mechanical closing systems including elastic unitsserving as a flexible waist band for fluid-absorbents articles, such aspants or pull-ups. The elastic units enabling the fluid-absorbentarticle to be pulled down by the wearer as e.g. a training pant.

Suitable pants-shaped fluid-absorbent article has front section, rearsection, crotch section, side sections for connecting the front and rearsections in lateral direction, hip section, elastic waist region andliquid-tight outer layer. The hip section is arranged around the waistof the user. The disposable pants-shaped fluid-absorbent article(pull-up) has favorable flexibility, stretchability, leak-proof propertyand fit property, hence imparts excellent comfort to the wearer.

Suitable pull-ups comprising thermoplastic films, sheets and laminateshaving a low modulus, good tear strength and high elastic recovery.

Suitable closing systems may further comprise elastomerics for theproduction of elastic areas within the fastening devices of thefluid-absorbent article. Elastomerics provide a conformable fit of thefluid-absorbent article to the wearer at the waist and leg openings,while maintaining adequate performance against leakage.

Suitable elastomerics are elastomeric polymers or elastic adhesivematerials showing vapor permeability and liquid barrier properties.Preferred elastomerics are retractable after elongation to a lengthequivalent to its original length.

Suitable closing systems further comprise a belt system, comprisingwaist-belt and leg-belts for flexibly securing the fluid-absorbentarticle on the body of the wearer and to provide an improved fit on thewearer. Suitable waist-belts comprising two elastic belts, a leftelastic belt, and a right elastic belt. The left elastic belt isassociated with each of the left angular edges. The right elastic beltassociated with each of the right angular edges. The left and right sidebelts are elastically extended when the absorbent garment is laid flat.Each belt is connected to and extends between the front and rear of thefluid-absorbent article to form a waist hole and leg holes.

Preferably the belt system is made of elastomerics, thus providing aconformable fit of the fluid-absorbent article and maintaining adequateperformance against leakage.

D. Fluid-Absorbent Article Construction

The present invention further relates to the joining of the componentsand layers, films, sheets, tissues or substrates mentioned above toprovide the fluid-absorbent article. At least two, preferably alllayers, films, sheets, tissues or substrates are joined.

Suitable fluid-absorbent articles include a single- or multiplefluid-absorbent core-system. Preferably fluid-absorbent articles includea single- or double fluid-absorbent core-system.

Suitable fluid-storage layers of the fluid-absorbent core comprisinghomogenous or inhomogenous mixtures of fibrous materials comprisingfluid-absorbent polymer particles homogenously or inhomogenouslydispersed in it. Suitable fluid-storage layers of the fluid-absorbentcore including a layered fluid-absorbent core-system comprisinghomogenous mixtures of fibrous materials and optionally comprisingfluid-absorbent polymer particles, whereby each of the layers may beprepared from any fibrous material by means known in the art.

In order to immobilize the fluid-absorbent polymer particles, theadjacent layers are fixed by the means of thermoplastic materials,thereby building connections throughout the whole surface oralternatively in discrete areas of junction. For the latter case,cavities or pockets are built carrying the fluid-absorbent particles.The areas of junction may have a regular or irregular pattern, e.g.aligned with the longitudinal axis of the fluid-absorbent core or in apattern of polygons, e.g. pentagons or hexagons. The areas of junctionitself may be of rectangular, circular or squared shape with diametersbetween about 0.5 mm and 2 mm. Fluid-absorbent articles comprising areasof junction show a better wet strength.

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

In order to describe the present invention in detail, embodiments aregenerated which are described hereinafter.

Thus, preferred fluid-absorbent articles are subsequently described indetail.

Embodiment 1

One preferred embodiment of the present invention is described inEmbodiment 1 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a single fluid-absorbent core between (A) and (B) comprising        between 10 to 50% by weight fluid-absorbent polymer particles        based on the total absorbent core weight and including a        multi-layered fluid-storage section comprising the following        sequence:        -   1. a homogenous upper core fluff layer of hydrophilic            fibrous matrix of wood pulp fibers (cellulose fibers)            containing about 50% of the total fluff amount;        -   2. a fluid-absorbent layer comprising fluid-absorbent            polymer particles; suitable fluid-absorbent polymer            particles for such construction having a centrifuge            retention capacity (CRC) from about 32 to 60 g/g;        -   3. a homogenous lower core fluff layer of hydrophilic            fibrous matrix of wood pulp fibers (cellulose fibers)            containing about 50% of the total fluff amount and acting as            a dusting layer; and    -   (D) an air-through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 30 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the fluid-absorbent core having a size of about 150 to        about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 20107/156108, US 2008/0125735, andWO 2008/155722 A2, which explicitly forms part of the presentdisclosure.

Construction Example of Embodiment 1

The fluid-absorbent core consists of a multi-layered single core systemeach layer having a uniform rectangular size. The layeredfluid-absorbent core between (A) and (B) comprises a multi-layeredsystem of hydrophilic fibers (cellulose fibers, fluff pulp fibers). Thetotal fluff pulp weight is 20.45 g divided equally between upper core(1) and lower core (3). The density of the fluid-absorbent core is forthe front overall average 0.18 g/cm³, for the insult zone 0.17 g/cm³,for the back overall average 0.15 g/cm³. The basis weight of thefluid-absorbent core is for the front overall average 802.75 gsm, forthe insult zone 825.94 gsm, for the back overall average 766.14 gsm.

Fluid-absorbent layer (2) holds 31.38% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 9.34 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 1, example 2,exhibiting the following features and absorption profile:

CRC of 37.2 g/g

SFC of 10×10⁻⁷ cm³s/g

AUHL of 28.1 g/g AUL of 32 g/g Extractables of 3.1 wt. %

Residual monomers of 300 ppmMoisture content of 2.9 wt. %FSR of 0.59 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 37.5 cm; width: 10.0 cm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 50 gsm is rectangular shaped with dimensions of20 cm×10 cm and smaller than the fluid-absorbent core.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 1 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.6 cm    -   mechanical closure system with landing zone of dimension 18.3        cm×4.0 cm and flexiband closure tapes of 3.4 cm×1.0 cm; attached        to hook fastening tape of 3.4 cm×1.4 cm    -   Also incorporated is elasticated waistband located to the rear        of the product with dimensions of 14.6 cm×4.5 cm

Dimension of the fluid-absorbent article: length: 49.6 cm; front width:34.0 cm; crotch width: 24.0 cm; rear width: 34.3 cm.

Embodiment 2

A further preferred embodiment of the present invention is described inEmbodiment 2 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a thermalbond        layer (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a single fluid-absorbent core between (A) and (B) comprising        between 40 to 80% by weight fluid-absorbent polymer particles        based on the total absorbent core weight and including a        multi-layered fluid-storage section comprising the following        sequence:        -   1. a homogenous upper core fluff layer of hydrophilic            fibrous matrix of wood pulp fibers (cellulose fibers)            containing about 50% of the total fluff amount;        -   2. a fluid-absorbent layer comprising fluid-absorbent            polymer particles; suitable fluid-absorbent polymer            particles for such construction having a saline flow            conductivity (SFC) from about 35 to 100×10⁻⁷ cm³s/g;        -   3. a homogenous lower core fluff layer of hydrophilic            fibrous matrix of wood pulp fibers (cellulose fibers)            containing about 50% of the total fluff amount and acting as            a dusting layer; and    -   (D) an air-through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the fluid-absorbent core having a size of about 150 to        about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 2

The fluid-absorbent core consists of a multi-layered single core systemeach layer having a uniform rectangular size. The layeredfluid-absorbent core between (A) and (B) comprises a multi-layeredsystem of hydrophilic fibers (cellulose fibers, fluff pulp fibers). Thetotal fluff pulp weight is 12 g divided equally between upper core (1)and lower core (3). The density of the fluid-absorbent core is for thefront overall average 0.19 g/cm³, for the insult zone 0.20 g/cm³, forthe back overall average 0.18 g/cm³. The basis weight of thefluid-absorbent core is for the front overall average 989 gsm, for theinsult zone 1101 gsm, for the back overall average 664 gsm. Thethickness of the fluid-absorbent core has an average of 4.5 mm.

The fluid-absorbent layer (2) holds 56.5% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 12 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 1, example 5,exhibiting the following features and absorption profile:

CRC of 28.7 g/g

SFC of 51×10⁻⁷ cm³s/g

AUHL of 24.5 g/g AUL of 30.3 g/g Extractables of 2.6 wt. %

Residual monomers of 250 ppmMoisture content of 1.6 wt. %FSR of 0.51 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 38 cm; width: 10 cm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 50 gsm is rectangular shaped with dimensions of24 cm×8 cm and smaller than the fluid-absorbent core.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 1 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.6 cm    -   mechanical closure system with landing zone of dimension 18.3        cm×4.0 cm and flexiband closure tapes of 3.4 cm×1.0 cm; attached        to hook fastening tape of 3.4 cm×1.4 cm    -   Also incorporated is elasticated waistband located to the rear        of the product with dimensions of 14.6×4.5 cm

Dimension of the fluid-absorbent article: length: 49.6 cm; front width:34.0 cm; crotch width: 24.0 cm; rear width: 34.3 cm.

Embodiment 3

A further preferred embodiment of the present invention is described inEmbodiment 3 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond web        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a single fluid-absorbent core between (A) and (B) comprising        a mixture of wood pulp fibers (cellulose fibers) and between 10        to 50% by weight homogeneously distributed fluid-absorbent        polymer particles within the fluid-absorbent core (C); suitable        fluid-absorbent polymer particles for such construction having a        centrifuge retention capacity (CRC) from about 32 to 60 g/g; the        fluid-absorbent core is further comprising a dusting layer        adjacent to the liquid-impervious layer (B) and underlying the        fluid-absorbent core above; the dusting layer is a fibrous layer        comprising fluff only (cellulose fibers); and    -   (D) an air-through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 30 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the fluid-absorbent core having a size of about 150 to        about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 3

The fluid-absorbent core consists of a single fluid-absorbent Corebetween (A) and (B) comprising a mixture of wood pulp fibers (cellulosefibers) and 37.11% by weight homogeneously distributed fluid-absorbentpolymer particles within the fluid-absorbent core (C) having a uniformrectangular size. The quantity of fluid-absorbent polymer particleswithin the fluid-absorbent core is 11.38 g. The total fluff pulp weightis 19.25 g. The density of the fluid-absorbent core is for the frontoverall average 0.22 g/cm³, for the insult zone 0.18 g/cm³, for the backoverall average 0.18 g/cm³. The basis weight of the fluid-absorbent coreis for the front overall average 914.18 gsm, for the insult zone 925.47gsm, for the back overall average 886.32 gsm.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 1, example 3,exhibiting the following features and absorption profile:

CRC of 34.8 g/g

SFC of 16×10⁻⁷ cm³s/g

AUHL of 27.2 g/g AUL of 32.3 g/g Extractables of 3.0 wt. %

Residual monomers of 320 ppmMoisture content of 1.1 wt. %FSR of 0.58 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 39.2 cm; width: 10.0 cm.

The thickness of the fluid-absorbent core has an average of 4.7 mm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 40 gsm is rectangular shaped with dimensions of24.4 cm×8.6 cm and smaller than the fluid-absorbent core.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 1 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.0 cm    -   mechanical closure system with landing zone of dimension 18.9        cm×3.8 cm and flexiband closure tapes of 1.6 cm×3.4 cm; attached        to hook fastening tape of 1.3 cm×3.4 cm    -   also incorporated is elasticated waistband located to the rear        of the product with dimensions of 10.8 cm×2.8 cm

Dimension of the fluid-absorbent article: length: 47.8 cm; front width:31.5 cm; crotch width: 20.6 cm; rear width: 31.1 cm.

Embodiment 4

A further preferred embodiment of the present invention is described inEmbodiment 4 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond web        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a single fluid-absorbent core between (A) and (B) comprising        a mixture of wood pulp fibers (cellulose fibers) and between 40        to 80% by weight homogeneously distributed fluid-absorbent        polymer particles within the fluid-absorbent core; suitable        fluid-absorbent polymer particles for such construction having a        saline flow conductivity (SFC) from about 35 to 100×10⁻⁷ cm³s/g;        and    -   (D) a system of two acquisition-distribution layers between (A)        and (C), comprising an upper resinbonded layer having a basis        weight of 40 to 80 gsm; the upper acquisition-distribution layer        is rectangular shaped having a size of about 150 to about 250        cm²; the lower acquisition-distribution layer comprising of        modified cellulosic fibers (e.g. from Buckeye Technologies Inc.)        having a basis weight of 40 to 80 gsm and a size of about 100 to        about 300 cm²; both acquisition-distribution layers are smaller        than the fluid-absorbent core.

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 20081155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 4

The fluid-absorbent core consists of a single fluid-absorbent corebetween (A) and (B) comprising a mixture of wood pulp fibers (cellulosefibers) and 67.12% by weight homogeneously distributed fluid-absorbentpolymer particles within the fluid-absorbent core (C) having a uniformrectangular size. The fluid-absorbent core is encapsulated by wrappingwith a spunbond material having a basis weight of 10 gsm. The quantityof fluid-absorbent polymer particles within the fluid-absorbent core is12.18 g. The total fluff pulp weight is 5.95 g. The density of thefluid-absorbent core is for the front overall average 0.19 g/cm³, forthe insult zone 0.18 g/cm³, for the back overall average 0.18 g/cm³. Thebasis weight of the fluid-absorbent core is for the front overallaverage 965.79 gsm, for the insult zone 913.38 gsm, for the back overallaverage 658.85 gsm.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009598 A1, example 7, exhibitingthe following features and absorption profile:

CRC of 20.9 g/g

SFC of 149×10⁻⁷ cm³s/g

AUHL of 18.8 g/g AUL of 22.3 g/g Extractables of 1.6 wt. %

Residual monomers of 330 ppmMoisture content of 16.6 wt. %FSR of 0.28 g/gs

PSD of 200 to 600 μm Anticaking of 3

Dimension of the fluid-absorbent core: length: 40.0 cm; width: 10.0 cm.

The thickness of the fluid-absorbent core has an average of 4.4 mm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 60 gsm is rectangular shaped with dimensions of24.0 cm×7.5 cm and smaller than the fluid-absorbent core.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.3 cm    -   mechanical closure system with landing zone of dimension 19.8        cm×5.0 cm and flexiband closure tapes of 3.5 cm×2.7 cm        consisting of pressure sensitive adhesive zone 3.5 cm×1.5 cm and        mechanical hook of 3.5 cm×1.2 cm

For improving the fit of the fluid-absorbent article, the product ofembodiment 4 provides a stretchable side panel and a reduced widthchassis.

Dimension of the fluid-absorbent article: length: 48.0 cm; front width:32.3 cm; crotch width: 20.3 cm; rear width: 31.0 cm.

Embodiment 5

A further preferred embodiment of the present invention is described inEmbodiment 5 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a double fluid-absorbent core between (A) and (B) comprising        a homogenous mixture of wood pulp fibers (cellulose fibers) and        fluid-absorbent polymer particles as primary core and a layered        secondary fluid-absorbent core; the total double fluid-absorbent        core comprising the following sequence:        -   1. a homogenous primary core of hydrophilic fibrous matrix            of wood pulp fibers (cellulose fibers) comprising between 10            to 50% by weight fluid-absorbent polymer particles based on            the primary absorbent core weight; the primary core contains            about 30% of the total fluff amount; suitable            fluid-absorbent polymer particles for such construction            having a centrifuge retention capacity (CRC) from about 32            to 60 g/g;        -   2. a secondary core upper fluff layer of hydrophilic fibrous            matrix of wood pulp fibers (cellulose fibers); the secondary            core upper layer contains about 35% of the total fluff            amount;        -   3. a fluid-absorbent layer comprising between 10 to 50% by            weight fluid-absorbent polymer particles based on the            secondary absorbent core weight; suitable fluid-absorbent            polymer particles for such construction having a centrifuge            retention capacity CRC from about 32 to 60 g/g;        -   4. a secondary core lower fluff layer of hydrophilic fibrous            matrix of wood pulp fibers (cellulose fibers) acting as a            dusting layer; the lower core contains about 35% of the            total fluff amount; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 30 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 5

The total fluid-absorbent core includes a double-core system, theprimary and secondary cores each having an almost uniform rectangularsize. The primary core is smaller than the secondary core and ispositioned 6 cm from the front distal edge of the secondary core and 10cm from the rear distal edge of the secondary core and is 9 cm in width.The primary fluid-absorbent core between (A) and (B) comprising ahomogenous mixture of hydrophilic fibrous matrix of wood pulp fibers and25% by weight of water absorbent polymer particles. The primary core hasa total weight of 8 g. The secondary core is a multi-layered system ofhydrophilic fibrous matrix of wood pulp fibers (cellulose fibers) and30% by weight fluid-absorbent polymer particles. The quantity offluid-absorbent polymer particles within the secondary fluid-absorbentcore is 6.0 g. The density of the fluid-absorbent core is for the frontoverall average 0.15 g/cm³, for the insult zone 0.19 g/cm³, for the backoverall average 0.18 g/cm³. The basis weight of the fluid-absorbent coreis for the front overall average 790.63 gsm, for the insult zone 1121.38gsm, for the back overall average 976.83 gsm.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 2, example 3,exhibiting the following features and absorption profile:

CRC of 35.7 g/g

SFC of 10×10⁻⁷ cm³s/g

AUHL of 29.1 g/g AUL of 35.0 g/g Extractables of 3.0 wt. %

Residual monomers of 250 ppmMoisture content of 0.9 wt. %FSR of 0.59 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the secondary fluid-absorbent core: length: 40.8 cm; frontwidth: 10.5 cm; crotch width: 9.3 cm; rear width: 10.3 cm.

The total thickness of both fluid-absorbent cores has an average of 5.4mm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 40 gsm is rectangular shaped and smaller thanthe primary fluid-absorbent core having a size of 19.7 cm×7.6 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.8 cm    -   mechanical closure system with landing zone of dimension 22.0        cm×4.0 cm and flexiband closure tapes of 3.4 cm×1.5 cm; attached        to hook fastening tape of 3.4 cm×1.4 cm

Dimension of the fluid-absorbent article: length: 48.0 cm; front width:29.7 cm; crotch width: 22.0 cm; rear width: 31.6 cm.

Embodiment 6

A further preferred embodiment of the present invention is described inEmbodiment 6 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a double fluid-absorbent core between (A) and (B) comprising        a homogenous mixture of wood pulp fibers (cellulose fibers) and        fluid-absorbent polymer particles as primary core and a layered        secondary fluid-absorbent core; the total double fluid-absorbent        core comprising the following sequence:        -   1. a homogenous primary core of hydrophilic fibrous matrix            of wood pulp fibers (cellulose fibers) comprising between 40            to 80% by weight fluid-absorbent polymer particles based on            the primary absorbent core weight; the primary core contains            about 50% of the total fluff amount; suitable            fluid-absorbent polymer particles for such construction            having a saline flow conductivity (SFC) from about 35 to            100×10⁻⁷ cm³s/g;        -   2. a secondary core upper fluff layer of hydrophilic fibrous            matrix of wood pulp fibers (cellulose fibers); the secondary            core upper layer contains about 25% of the total fluff            amount;        -   3. a fluid-absorbent layer comprising between 40 to 80% by            weight fluid-absorbent polymer particles based on the            secondary absorbent core weight; suitable fluid-absorbent            polymer particles for such construction having a saline flow            conductivity (SFC) from about 35 to 100×10⁻⁷ cm³s/g;        -   4. a secondary core lower fluff layer of hydrophilic fibrous            matrix of wood pulp fibers (cellulose fibers) acting as a            dusting layer; the lower core contains about 25% of the            total fluff amount; and    -   (D) an air through (bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 6

The total fluid-absorbent core includes a double-core system, theprimary and secondary cores each having an almost uniform rectangularsize. The primary core is smaller than the secondary core and ispositioned 6 cm from the front distal edge of the secondary core and 10cm from the rear distal edge of the secondary core and is 9 cm in width.The primary fluid-absorbent core between (A) and (B) comprising ahomogenous mixture of hydrophilic fibrous matrix of wood pulp fibers and50% by weight of water absorbent polymer particles. The primary core hasa total weight of 8 g. The secondary core is a multi-layered system ofhydrophilic fibrous matrix of wood pulp fibers (cellulose fibers) and50% by weight fluid-absorbent polymer particles. The quantity offluid-absorbent polymer particles within the secondary fluid-absorbentcore is 10.0 g. The density of the fluid-absorbent core is for the frontoverall average 0.19 g/cm³, for the insult zone 0.19 g/cm³, for the backoverall average 0.18 g/cm³. The basis weight of the fluid-absorbent coreis for the front overall average 813.46 gsm, for the insult zone12109.15 gsm, for the back overall average 986.27 gsm.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 2, example 6,exhibiting the following features and absorption profile:

CRC of 27.7 g/g

SEC of 65×10⁻⁷ cm³s/g

AUHL of 23.4 g/g AUL of 28.9 g/g Extractables of 3.3 wt. %

Residual monomers of 280 ppmMoisture content of 1.2 wt. %FSR of 0.34 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the secondary fluid-absorbent core: length: 40.8 cm; frontwidth: 10.0 cm; crotch width: 9.0 cm; rear width: 10.0 cm.

The total thickness of both fluid-absorbent cores has an average of 3.9mm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 60 gsm is rectangular shaped and smaller thanthe primary fluid-absorbent core having a size of 19.0 cm×7.6 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.8 cm    -   mechanical closure system with landing zone of dimension 22.0        cm×4.0 cm and flexiband closure tapes of 3.4 cm×1.5 cm; attached        to hook fastening tape of 3.4 cm×1.4 cm

Dimension of the fluid-absorbent article: length: 48.0 cm; front width:29.7 cm; crotch width: 20.0 cm; rear width: 31.6 cm.

Embodiment 7

A further preferred embodiment of the present invention is described inEmbodiment 7 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a double fluid-absorbent core between (A) and (B) comprising        a homogenous mixture of wood pulp fibers (cellulose fibers) and        polymer particles for each the primary core and the secondary        fluid-absorbent core; the total double fluid-absorbent core        comprising:        -   1. a homogenous primary core of hydrophilic fibrous matrix            of wood pulp fibers (cellulose fibers) comprising between 10            to 50% by weight fluid-absorbent polymer particles based on            the primary absorbent core weight; the primary core contains            about 30% of the total fluff amount; suitable            fluid-absorbent polymer particles for such construction            having a centrifuge retention capacity (CRC) from about 32            to 60 g/g;        -   2. a homogenous secondary core of hydrophilic fibrous matrix            of wood pulp fibers (cellulose fibers) comprising between 10            to 50% by weight fluid-absorbent polymer particles based on            the secondary absorbent core weight; the secondary core            contains about 70% of the total fluff amount; suitable            fluid-absorbent polymer particles for such construction            having a centrifuge retention capacity (CRC) from about 32            to 60 g/g; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 30 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/01125735, andWO 2008/155722 A2, which explicitly forms part of the presentdisclosure.

Construction Example of Embodiment 7

The total fluid-absorbent core includes a double-core system, theprimary and secondary cores each having an almost uniform rectangularsize. The primary core is smaller than the secondary core and ispositioned 6 cm from the front distal edge of the secondary core and 10cm from the rear distal edge of the secondary core and is 9 cm in width.The primary fluid-absorbent core between (A) and the secondaryfluid-absorbent core comprising a homogenous mixture of hydrophilicfibrous matrix of wood pulp fibers and 25% by weight of water absorbentpolymer particles. The primary core has a total weight of 8 g. Thesecondary core between the primary core and (B) comprising a homogenousmixture of hydrophilic fibrous matrix of wood pulp fibers and 30% byweight of water absorbent polymer particles. The quantity offluid-absorbent polymer particles within the secondary fluid-absorbentcore is 6.0 g. The secondary core has a total weight of 20 g. Thedensity of the fluid-absorbent core is for the front overall average0.15 g/cm³, for the insult zone 0.19 g/cm³, for the back overall average0.18 g/cm³. The basis weight of the fluid-absorbent core is for thefront overall average 790.63 gsm, for the insult zone 1121.38 gsm, forthe back overall average 976.83 gsm.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 2, example 3,exhibiting the following features and absorption profile:

CRC of 35.7 g/g

SFC of 10×10⁻⁷ cm³s/g

AUHL of 29.1 g/g AUL of 35.0 g/g Extractables of 3.0 wt. %

Residual monomers of 250 ppmMoisture content of 0.9 wt. %FSR of 0.59 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the secondary fluid-absorbent core: length: 40.8 cm; frontwidth: 10.5 cm; crotch width: 9.3 cm; rear width: 10.3 cm

The total thickness of both fluid-absorbent cores has an average of 5.4mm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 40 gsm is rectangular shaped and smaller thanthe primary fluid-absorbent core having a size of 19.7 cm×7.6 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.8 cm    -   mechanical closure system with landing zone of dimension 22.0        cm×4.0 cm and flexiband closure tapes of 3.4 cm×1.5 cm; attached        to hook fastening tape of 3.4 cm×1.4 cm

Dimension of the fluid-absorbent article: length: 48.0 cm; front width:29.7 cm; crotch width: 22.0 cm; rear width: 31.6 cm.

Embodiment 8

A further preferred embodiment of the present invention is described inEmbodiment 8 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a double fluid-absorbent core between (A) and (B) comprising        a homogenous mixture of wood pulp fibers (cellulose fibers) and        polymer particles for each the primary core and the secondary        fluid-absorbent core; the total double fluid-absorbent core        comprising:        -   1. a homogenous primary core of hydrophilic fibrous matrix            of wood pulp fibers (cellulose fibers) comprising between 40            to 80% by weight fluid-absorbent polymer particles based on            the primary absorbent core weight; the primary core contains            about 50% of the total fluff amount; suitable            fluid-absorbent polymer particles for such construction            having a saline flow conductivity (SFC) from about 35 to            100×10⁻⁷ cm³s/g;        -   2. a homogenous secondary core of hydrophilic fibrous matrix            of wood pulp fibers (cellulose fibers) comprising between 40            to 70% by weight fluid-absorbent polymer particles based on            the secondary absorbent core weight; the secondary core            contains about 50% of the total fluff amount; suitable            fluid-absorbent polymer particles for such construction            having a saline flow conductivity (SFC) from about 35 to            100×10⁻⁷ cm³s/g; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 8

The total fluid-absorbent core includes a double-core system, theprimary and secondary cores each having an almost uniform rectangularsize. The primary core is smaller than the secondary core and ispositioned 6 cm from the front distal edge of the secondary core and 10cm from the rear distal edge of the secondary core and is 9 cm in width.The primary fluid-absorbent core between (A) and the secondaryfluid-absorbent core comprising a homogenous mixture of hydrophilicfibrous matrix of wood pulp fibers and 28.6% by weight of waterabsorbent polymer particles. The primary core has a total weight of 8 g.The secondary core between the primary core and (B) comprising ahomogenous mixture of hydrophilic fibrous matrix of wood pulp fibers and71.4% by weight of water absorbent polymer particles. The quantity offluid-absorbent polymer particles within the secondary fluid-absorbentcore is 10.0 g. The secondary core has a total weight of 20 g. Thedensity of the fluid-absorbent core is for the front overall average0.15 g/cm³, for the insult zone 0.19 g/cm³, for the back overall average0.18 g/cm³. The basis weight of the fluid-absorbent core is for thefront overall average 790.63 gsm, for the insult zone 1121.38 gsm, forthe back overall average 976.83 gsm.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 2, example 6,exhibiting the following features and absorption profile:

CRC of 27.7 g/g

SFC of 65×10⁻⁷ cm³s/g

AUHL of 23.4 g/g AUL of 28.9 g/g Extractables of 3.3 wt. %

Residual monomers of 280 ppmMoisture content of 1.2 wt. %FSR of 0.34 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the secondary fluid-absorbent core: length: 40.8 cm; frontwidth: 10.5 cm; crotch width: 9.3 cm; rear width: 10.3 cm.

The total thickness of both fluid-absorbent cores has an average of 5.4mm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 60 gsm is rectangular shaped and smaller thanthe primary fluid-absorbent core having a size of 19.7 cm×7.6 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.8 cm    -   mechanical closure system with landing zone of dimension 22.0        cm×4.0 cm and flexiband closure tapes of 3.4 cm×1.5 cm; attached        to hook fastening tape of 3.4 cm×1.4 cm

Dimension of the fluid-absorbent article: length: 48.0 cm; front width:29.7 cm; crotch width: 20.0 cm; rear width: 31.6 cm.

Embodiment 9

A further preferred embodiment of the present invention is described inEmbodiment 9 (pantiliner) hereinafter. Thus, a preferred fluid-absorbentarticle comprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a single fluid-absorbent core between (A) and (B) comprising        between 10 to 50% by weight fluid-absorbent polymer particles        based on the total absorbent core weight and including a        multi-layered fluid-storage section comprising the following        sequence:        -   1. a homogenous upper core fluff layer of hydrophilic            fibrous matrix of wood pulp fibers (cellulose fibers)            containing about 50% of the total fluff amount;        -   2. a fluid-absorbent layer comprising fluid-absorbent            polymer particles; suitable fluid-absorbent polymer            particles for such construction having a centrifuge            retention capacity (CRC) from about 32 to 60 g/g; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 9

The fluid-absorbent core consists of a double-layered single core systemeach layer having a uniform rectangular size. The layeredfluid-absorbent core between (A) and (B) comprises a double-layeredsystem of hydrophilic fibers (cellulose fibers, fluff pulp fibers), eachlayer having an almost uniform rectangular size. The fluid-absorbentcore is encapsulated by wrapping with a spunbond material having a basisweight of 10 gsm. The density of the fluid-absorbent core is for thefont overall average 0.16 g/cm³, for the insult zone 0.14 g/cm³, for theback overall average 0.16 g/cm³. The basis weight of the fluid-absorbentcore is for the front overall average 598.16 gsm, for the insult zone596.94 gsm, for the back overall average 626.23 gsm. The thickness ofthe fluid-absorbent core has an average of 3.8 mm.

The fluid-absorbent core holds 31.38% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 9.34 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 1, example 2,exhibiting the following features and absorption profile:

CRC of 37.2 g/g

SFC of 10×10⁻⁷ cm³s/g

AUHL of 28.1 g/g AUL of 32 g/g Extractables of 3.1 wt. %

Residual monomers of 300 ppmMoisture content of 2.9 wt. %FSR of 0.59 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 40.8 cm; front width:14.2 cm; crotch width: 14.5 cm; rear width: 14.1 cm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 35.7 gsm is rectangular shaped and smaller thanthe fluid-absorbent core having a size of 24.0 cm×9.2 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 5 cuff        elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.7 cm

For improving the fit of the fluid-absorbent article, the pantiliner ofembodiment 10 provides stretchable bands.

Dimension of the fluid-absorbent article: length: 47.9 cm; front width:31.3 cm; crotch width: 15.4 cm; rear width: 31.3 cm.

Embodiment 10

A further preferred embodiment of the present invention is described inEmbodiment 10 (pantiliner) hereinafter. Thus, a preferredfluid-absorbent article comprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a single fluid-absorbent core between (A) and (B) comprising        between 40 to 80% by weight fluid-absorbent polymer particles        based on the total absorbent core weight and including a        multi-layered fluid-storage section comprising the following        sequence:        -   1. a homogenous upper core fluff layer of hydrophilic            fibrous matrix of wood pulp fibers (cellulose fibers)            containing about 50% of the total fluff amount;        -   2. a fluid-absorbent layer comprising fluid-absorbent            polymer particles; suitable fluid-absorbent polymer            particles for such construction having a saline flow            conductivity (SFC) from about 35 to 100×10⁻⁷ cm³s/g; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 10

The fluid-absorbent core consists of a double-layered single core systemeach layer having a uniform rectangular size. The layeredfluid-absorbent core between (A) and (B) comprises a double-layeredsystem of hydrophilic fibers (cellulose fibers, fluff pulp fibers), eachlayer having an almost uniform rectangular size. The fluid-absorbentcore is encapsulated by wrapping with a spunbond material having a basisweight of 10 gsm. The density of the fluid-absorbent core is for thefont overall average 0.16 g/cm³, for the insult zone 0.14 g/cm³, for theback overall average 0.16 g/cm³. The basis weight of the fluid-absorbentcore is for the front overall average 598.16 gsm, for the insult zone596.94 gsm, for the back overall average 626.23 gsm. The thickness ofthe fluid-absorbent core has an average of 3.8 mm.

The fluid-absorbent core holds 59.05% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 11.9 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009598 A1, example 6, exhibitingthe following features and absorption profile:

CRC of 24.5 g/g

SFC of 41×10⁻⁷ cm³s/g

AUHL of 18.6 g/g AUL of 24.1 g/g Extractables of 3.8 wt. %

Residual monomers of 310 ppmMoisture content of 15.9 wt. %FSR 0.93 g/gs

PSD of 200 to 600 μm Anticaking of 3

Dimension of the fluid-absorbent core: length: 40.8 cm; front width:14.2 cm; crotch width: 14.5 cm; rear width: 14.1 cm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 35.7 gsm is rectangular shaped and smaller thanthe fluid-absorbent core having a size of 24.0 cm×9.2 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 5 cuff        elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.7 cm

For improving the fit of the fluid-absorbent article, the pantiliner ofembodiment 10 provides stretchable bands.

Dimension of the fluid-absorbent article: length: 47.9 cm; front width:31.3 cm; crotch width: 15.4 cm; rear width: 31.3 cm.

Embodiment 11

A further preferred embodiment of the present invention is described inEmbodiment 11 (pantiliner) hereinafter. Thus, a preferredfluid-absorbent article comprising

-   -   (A) an upper liquid-pervious layer comprising a spunbond layer        (three piece coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a high-loaded single fluid-absorbent core between (A)        and (B) comprising between 55 to 95% by weight fluid-absorbent        polymer particles based on the total absorbent core weight and        including a multi-layered fluid-storage section comprising the        following sequence:        -   1. a homogenous upper core layer of hydrophilic synthetic            fibers (fibrous matrix) containing about 95% of the total            fluff amount;        -   2. a high-loaded fluid-absorbent layer comprising            fluid-absorbent polymer particles; suitable fluid-absorbent            polymer particles for such construction having a saline flow            conductivity (SFC) from about 50 to 150×10⁻⁷ cm³s/g; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core having a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 20107/156108, US 2008/0125735, andWO 2008/155722 A2, which explicitly forms part of the presentdisclosure.

Construction Example of Embodiment 11

The fluid-absorbent core consists of a double-layered high-loaded singlecore system each layer having a uniform rectangular size. The layeredfluid-absorbent core between (A) and (B) comprises a double-layeredsystem of hydrophilic fibers (synthetic fibers), each layer having arectangular size. The fluid-absorbent core is encapsulated by wrappingwith a spunbond material having a basis weight of 10 gsm. The density ofthe fluid-absorbent core is for the font overall average 0.20 g/cm³, forthe insult zone 0.20 g/cm³, for the back overall average 0.21 g/cm³. Thebasis weight of the fluid-absorbent core is for the front overallaverage 551.51 gsm, for the insult zone 585.71 gsm, for the back overallaverage 569.63 gsm. The thickness of the fluid-absorbent core has anaverage of 2.9 mm.

The fluid-absorbent core holds 81.6% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 12.9 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 1, example 5,exhibiting the following features and absorption profile:

CRC of 28.7 g/g

SFC of 51×10⁻⁷ cm³s/g

AUHL of 24.5 g/g AUL of 30.3 g/g Extractables of 2.6 wt. %

Residual monomers of 250 ppmMoisture content of 1.6 wt. %FSR 0.51 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 40.8 cm; front width:14.2 cm; crotch width: 14.5 cm; rear width: 14.1 cm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 35.7 gsm is rectangular shaped and smaller thanthe fluid-absorbent core having a size of 24.0 cm×9.2 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 5 cuff        elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.7 cm    -   wetness indicator at the lower side of the liquid-impervious        layer (B)

Dimension of the fluid-absorbent article: length: 47.9 cm; front width:31.3 cm; crotch width: 15.4 cm; rear width: 31.3 cm

Embodiment 12

A further preferred embodiment of the present invention is described inEmbodiment 12 (pantiliner) hereinafter. Thus, a preferredfluid-absorbent article comprising

-   -   (A) an upper liquid-pervious layer comprising a thermobond layer        (coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a high-loaded single fluid-absorbent core between (A)        and (B) comprising between 55 to 95% by weight fluid-absorbent        polymer particles based on the total absorbent core weight and        including a fluid-storage section comprising a high-loaded mixed        fluid-absorbent layer wrapped with a homogenous layer of        hydrophilic synthetic fibers; said high-loaded fluid-absorbent        layer comprises fluid-absorbent polymer particles; suitable        fluid-absorbent polymer particles for such construction having a        saline flow conductivity (SFC) from about 50 to 150×10⁻⁷ cm³s/g;        said homogenous wrapping of hydrophilic synthetic fibers        contains about 95% of the total fluff amount; and    -   (D) an air through bonded acquisition-distribution layer        between (A) and (C) having a basis weight of 40 to 80 gsm; the        acquisition-distribution layer is rectangular shaped and smaller        than the primary fluid-absorbent core haying a size of about 150        to about 250 cm².

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 2004/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/01125735, andWO 2008/155722 A2, which explicitly forms part of the presentdisclosure.

Construction Example of Embodiment 12

The fluid-absorbent core consists of a high-loaded single core systemhaving a uniform rectangular size. The fluid-absorbent core between (A)and (B) comprises a fluid-storage section comprising a high-loadedfluid-absorbent layer wrapped in a homogenous layer of hydrophilicsynthetic fibers. The fluid-absorbent core is encapsulated by wrappingit both in a C-wrap and a full wrap configuration with a spunbondmaterial having a basis weight of 10 gsm. The density of thefluid-absorbent core is for the font overall average 0.16 g/cm³, for theinsult zone 0.25 g/cm³, for the back overall average 0.19 g/cm³. Thebasis weight of the fluid-absorbent core is for the front overallaverage 436.86 gsm, for the insult zone 707.74 gsm, for the back overallaverage 555.73 gsm. The thickness of the fluid-absorbent core has anaverage of 3.0 mm.

The fluid-absorbent core holds 80.3% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 11.8 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009598 A1, example 7, exhibitingthe following features and absorption profile:

CRC of 20.9 g/g

SFC of 149×10⁻⁷ cm³s/g

AUHL of 18.8 g/g AUL of 22.3 g/g Extractables of 1.6 wt. %

Residual monomers of 330 ppmMoisture content of 16.6 wt. %FSR 0.28 g/gs

PSD of 200 to 600 μm Anticaking of 3

Dimension of the fluid-absorbent core: length: 40.8 cm; front width:14.2 cm; crotch width: 14.5 cm; rear width: 14.1 cm.

An air through bonded acquisition-distribution layer between (A) and (C)having a basis weight of 35.7 gsm is rectangular shaped and smaller thanthe fluid-absorbent core having a size of 24.0 cm×9.2 cm.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 5 cuff        elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.7 cm

For improving the fit of the fluid-absorbent article, the stretchablepant of embodiment 12 provides elastics from spandex type fibers.

Dimension of the fluid-absorbent article: length: 47.9 cm; front width:31.3 cm; crotch width: 15.4 cm; rear width: 31.3 cm.

Embodiment 13

A further preferred embodiment of the present invention is described inEmbodiment 13 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbonded layer        (coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a high-loaded single fluid-absorbent core between (A)        and (B) comprising between 55 to 95% by weight fluid-absorbent        polymer particles based on the total absorbent core weight        including a fluid-storage section comprising a high-loaded        fluid-absorbent layer wrapped with a spunbond material; said        high-loaded fluid-absorbent layer comprises fluid-absorbent        polymer particles; suitable fluid-absorbent polymer particles        for such construction having a saline flow conductivity (SFC)        from about 50 to 150×10⁻⁷ cm³s/g; said homogenous wrapping of        spunbond material contains about 100% of the total fluff amount;        and    -   (D) a system of two acquisition-distribution layers between (A)        and (C), comprising an upper resinbonded layer having a basis        weight of 40 to 80 gsm; the upper acquisition-distribution layer        is rectangular shaped having a size of about 150 to about 250        cm²; the lower acquisition-distribution layer comprising of        synthetic fibers having a basis weight of 40 to 80 gsm and a        size of about 100 to about 300 cm²; the upper        acquisition-distribution layer is smaller than the lower        acquisition-distribution layer; both acquisition-distribution        layers are smaller than the fluid-absorbent core.

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 20(14/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 13

The fluid-absorbent core consists of a high-loaded mixed single coresystem having an almost uniform rectangular size. The fluid-absorbentcore between (A) and (B) comprises a fluid-storage section comprising ahigh-loaded fluid-absorbent layer wrapped in a homogenous layer ofhydrophilic spunbond fibers having a basis weight of 10 gsm. The densityof the fluid-absorbent core is for the front overall average 0.20 g/cm³,for the insult zone 0.19 g/cm³, for the back overall average 0.19 g/cm³.The basis weight of the fluid-absorbent core is for the front overallaverage 1114 gsm, for the insult zone

1007 gsm, for the back overall average 658 gsm. The thickness of thefluid-absorbent core has an average of 4.5 mm.

The fluid-absorbent layer holds 67.2% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 14.1 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 1, example 5,exhibiting the following features and absorption profile:

CRC of 28.7 g/g

SFC of 51×10⁻⁷ cm³s/g

AUHL of 24.4 g/g AUL of 30.3 g/g Extractables of 2.6 wt. %

Residual monomers of 250 ppmMoisture content of 1.6 wt. %FSR 0.51 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 43.0 cm; front width:11.5 cm; crotch width: 7.2 cm; rear width: 12.1 cm.

The upper air through bonded acquisition-distribution layer between (A)and the lower acquisition-distribution layer having a basis weight of65.7 gsm is rectangular shaped with dimensions of 24.9 cm×7 cm. Thelower air through bonded acquisition-distribution layer between theupper acquisition-distribution layer and (C) is rectangular shaped withdimensions of 24.9 cm×7.5 cm. Both acquisition-distribution layers aresmaller than the fluid-absorbent core.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 3 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 3.4 cm    -   mechanical closure system with landing zone of dimension 14.9        cm×3.8 cm and adhesive closure tapes of 3.0 cm×1.3 cm; attached        to hook fastening tape of 3.0 cm×1.3 cm

Dimension of the fluid-absorbent article: length: 50.9 cm; front width:24.5 cm; crotch width: 24.3 cm; rear width: 24.5 cm.

Embodiment 14

A further preferred embodiment of the present invention is described inEmbodiment 14 hereinafter. Thus, a preferred fluid-absorbent articlecomprising

-   -   (A) an upper liquid-pervious layer comprising a spunbonded layer        (coverstock);    -   (B) a lower liquid-impervious layer comprising a composite of        breathable polyethylene film and spunbond nonwoven;    -   (C) a high-loaded single fluid-absorbent core between (A)        and (B) comprising between 55 to 95% by weight fluid-absorbent        polymer particles based on the total absorbent core weight        including a fluid-storage section comprising a high-loaded        fluid-absorbent layer wrapped with a spunbond material; said        high-loaded fluid-absorbent layer comprises fluid-absorbent        polymer particles; suitable fluid-absorbent polymer particles        for such construction having a saline flow conductivity (SFC)        from about 50 to 150×10⁻⁷ cm³s/g; said homogenous wrapping of        spunbond material contains about 100% of the total fluff amount;        and    -   (D) a system of two acquisition-distribution layers between (A)        and (C), comprising an upper resinbonded layer having a basis        weight of 40 to 80 gsm; the upper acquisition-distribution layer        is rectangular shaped having a size of about 150 to about 250        cm²; the lower acquisition-distribution layer comprising of        synthetic fibers having a basis weight of 40 to 80 gsm and a        size of about 100 to about 300 cm²; the upper        acquisition-distribution layer is smaller than the lower        acquisition-distribution layer; both acquisition-distribution        layers are smaller than the fluid-absorbent core;

The construction of the products chassis and the components containedtherein is made and controlled by the discrete application of hotmeltadhesives as known to people skilled in the art. Examples would be e.g.Dispomelt 505B, Dispomelt Cool 1101, as well as other specific functionadhesives manufactured by National Starch or Henkel.

Ultra-thin high-loaded fluid-absorbent layers can be formed byimmobilization of fluid-absorbent polymer particles on a non-woven sheetusing hotmelt adhesives. Preferably the fluid-absorbent polymerparticles form longitudinal strips or discrete spots. Other patterns ofthe fluid-absorbent polymer particles are also possible.

In a preferred embodiment the ultra-thin high-loaded fluid-absorbentlayers comprise at least two sheets comprising immobilizedfluid-absorbent polymer particles.

Examples of ultra-thin high-loaded fluid-absorbent layers are describedin EP 1 293 187 A1, U.S. Pat. No. 6,972,011, EP 1 447 066 A1, EP 1 447067 A1, EP 1 609 448 A1, JP 20104/313580, US 2005/0137085, US2006/0004336, US 2007/0135785 WO 2008/155699 A1, WO 2008/155701 A2, WO2008/155702 A1, WO 2008/155710 A1, WO 2008/155711 A1, WO 2004/071363 A1,US 2003/0181115, WO 2005/097025, US 2007/156108, US 2008/0125735, and WO2008/155722 A2, which explicitly forms part of the present disclosure.

Construction Example of Embodiment 14

The fluid-absorbent core consists of a high-loaded mixed single coresystem having an almost uniform rectangular size. The fluid-absorbentcore between (A) and (B) comprises a fluid-storage section comprising ahigh-loaded fluid-absorbent layer wrapped in a homogenous layer ofhydrophilic spunbond fibers having a basis weight of 10 gsm. The densityof the fluid-absorbent core is for the front overall average 0.25 g/cm³,for the insult zone 0.25 g/cm³, for the back overall average 0.26 g/cm³.The basis weight of the fluid-absorbent core is for the front overallaverage 878.70 gsm, for the insult zone 1237.56 gsm, for the backoverall average 495.60 gsm. The thickness of the fluid-absorbent corehas an average of 3.1 mm.

The fluid-absorbent layer holds 100% by weight distributedfluid-absorbent polymer particles, the quantity of fluid-absorbentpolymer particles within the fluid-absorbent core is 14.14 g.

The fluid-absorbent polymer particles derived from dropletizationpolymerization as described in WO 2008/009580 A1, table 2, example 6,exhibiting the following features and absorption profile:

CRC of 27.7 g/g

SFC of 65×10⁻⁷ cm³s/g

AUHL of 23.4 g/g AUL of 28.9 g/g Extractables of 3.3 wt. %

Residual monomers of 280 ppmMoisture content of 1.2 wt. %FSR 0.34 g/gs

PSD of 200 to 600 μm Anticaking of 3

The fluid-absorbent polymer particles were remoisturized to a moisturecontent of 13% by weight.

Dimension of the fluid-absorbent core: length: 42.4 cm; front width:10.6 cm; crotch width: 10.2 cm; rear width: 10.5 cm.

The upper air through bonded acquisition-distribution layer between (A)and the lower acquisition-distribution layer having a basis weight of58.8 gsm is rectangular shaped with dimensions of 24.7 cm×7.3 cm. Thelower air through bonded acquisition-distribution layer between theupper acquisition-distribution layer and (C) is rectangular shaped withdimensions of 20.3 cm×8.2 cm. Both acquisition-distribution layers aresmaller than the fluid-absorbent core.

The fluid-absorbent article further comprises:

-   -   flat rubber elastics; elastics from spandex type fibers: 2 leg        elastics and 2 cuff elastics    -   leg cuffs from synthetic fibers showing the layer combination        SMS and having a basis weight of between 13 to 17 gsm and a        height of 4.4 cm    -   waistband: front: 13.7 cm×2.1 cm; rear: 14.8 cm×2.2 cm

Dimension of the fluid-absorbent article: length: 46.7 cm; front width;33.5 cm; crotch width; 16.0 cm; rear width: 33.5 cm.

The fluid-absorbent polymer particles and the fluid-absorbent articlesare tested by means of the test methods described below.

Methods:

The measurements should, unless stated otherwise, be carried out at anambient temperature of 23±2° C. and a relative atmospheric humidity of50±10%. The fluid-absorbent polymers are mixed thoroughly before themeasurement.

Rewet Value

This test consists of multiple insults of 0.9 wt. % NaCl solution indeionized water. The rewet is measured by the amount of fluid thearticle released under pressure. The rewet is measured after eachinsult.

The article is clamped nonwoven side up onto the inspection table. Theinsult point is marked on the article accordingly with regard to thetype and gender of the diaper to be tested (i.e. in the centre of thefluid-absorbent core for girl, 2.5 cm towards the front for unisex and 5cm towards the front for boy). A separatory funnel is positioned abovethe article so that the spout is 2 cm away from the surface and directlyabove the marked insult point.

For the primary insult 100 g of NaCl solution is placed into theseparation funnel. The NaCl solution is released with a flow rate of 7±1g/s. Next, the fluid is allowed to be absorbed by the article for 10minutes. After the 10 minutes have elapsed, 10 filter papers (Whatman®No. 1; 9 cm diameter) are placed over the insult point, this value isthe dry weight (D1). On top of the filter papers, a 2.5 kg circularweight (8 cm diameter) is added. After 2 minutes, the filter papers arere-weighed, this value is the wet weight (W1).

The rewet is calculated as follows:

Rewet Value[g]=W1−D1

For the rewet of the secondary insult the procedure for the primaryinsult is repeated. 50 g of NaCl solution and 20 filter papers are used.

For the rewet of the tertiary and following insults the procedure forthe primary insult is repeated. 50 g of NaCl solution and 30 filterpapers are used.

Rewet Under Load/Acquisition Time

This test determines acquisition time and the amount of fluid afluid-absorbent article releases after being maintained under pressurefollowing multiple separate insults. The rewet under load is measured bythe amount of fluid the article released under pressure. The rewet underload and the acquisition time are measured after each insult.

The article is clamped nonwoven side up onto the inspection table. Theinsult point is marked on the article accordingly with regard to thetype and gender of the diaper to be tested (i.e. in the centre of thefluid-absorbent core for girl, 2.5 cm towards the front for unisex and 5cm towards the front for boy). A 3.64 kg circular weight (10 cmdiameter) having a central opening (2.3 cm diameter) is placed with theopening on the previously marked insult point. A perspex tube ispositioned in the central opening.

For the primary insult 100 g of 0.9 wt. % NaCl solution is poured intothe perspex tube in one shot. The amount of time in seconds for thefluid to be fully absorbed into the article is recorded as acquisitiontime. After 10 minutes have elapsed from the time of liquid addition, 10filter papers (Whatman® No. 1; 9 cm diameter) are placed over the insultpoint, this value is the dry weight (W1). On top of the filter papers, a2.5 kg circular weight (8 cm diameter) is added. After 2 minutes, thefilter papers are reweighed, this value is the wet weight (W2).

The rewet under load is calculated as follows:

Rewet Under Load[g]=W2−W1

For the rewet under load of the secondary insult the procedure for theprimary insult is repeated. 50 g of NaCl solution and 20 filter papersare used.

For the rewet under load of the tertiary and following insults theprocedure for the primary insult is repeated. 50 g of NaCl solution and30 filter papers are used.

Density of the Fluid-Absorbent Core

This test determines the density of the fluid-absorbent core in thepoint of interest.

The fluid-absorbent article is clamped nonwoven side up onto theinspection table. The insult point is marked on the article accordinglywith regard to the type and gender of the diaper to be tested in thecentre of the fluid-absorbent core for girl, 2.5 cm towards the frontfor unisex and 5 cm towards the front for boy).

Next, a 6 cm×core width section is marked on the fluid-absorbent corewith the point of interest in the centre of the section. Three readingsof thickness of the section are taken using a Portable Thickness GaugeModel J100 (SDL Atlas, Inc.; Stockport; UK) and the average is recorded(T). The section of the fluid-absorbent core is cut out of and theweight of the cut out section is recorded (WT).

The density of the fluid-absorbent core is calculated as follows:

Density[g/cm³ ]=WT/(36 cm² ×T)

Floating Particle Fraction (FPF)

The floating particle fraction (FPF) is the weight percentage offluid-absorbing polymer particles having an apparent density of lessthan 1.33 g/cm³.

The test samples and the solvent have to be kept in closed containers toallow them to equilibrate to the laboratory temperature before removinga test portion to run the test. The test conditions are (23±2)° C. and(50±10) % relative humidity.

150 ml of methylene chloride (purity at least 99.9% by weight, CAS-Nr.75-09-2, e.g. Fluka 66740) are filled into a separating funnel (volume 1L, conical form/pear type, DIN ISO 4800) with PTFE-plug stopcock(minimum discharge diameter 6 mm). 50 g of the fluid-absorbent polymerparticles are slowly added to the solvent using a funnel (diameter 150mm). Then, employing pivoting movements, the particles are thoroughlymixed with the solvent. The particles must be completely wetted by thesolvent. Particles sticking to the funnel walls are then removed byflushing with 50 ml of additional methylene using a laboratory pipette.If particles remain on the funnel walls after flushing the test has tobe re-started. The resulting particle-solvent suspension is then settledfor 10 minutes.

Depending on the sample type a certain part of the particles may befloating on the surface of the liquid while the rest will sink to thebottom of the funnel. In the case that the complete sample sinks to thebottom and no particles are floating the test result is hereby definedas zero percent fluid-absorbent polymer particles having an apparentdensity of less than 1.33 g/cm³ (Floating particle fraction, FPF=0%).

In all other cases the particles floating on the surface of the liquidhave to be separated by opening the PTFE-stopcock of the separatingfunnel and thereby releasing the sunk part of the suspension. Thestopcock has to be opened wide enough to discharge the sunk particlestogether with circumfluent solvent and it has to be closed shortlybefore the floating phase interface reaches the stopcock. Particleshaving exactly the density of the solvent will neither sink nor floatand are attributed to the sunk fraction. The released particle-solventsuspension is poured onto a fluted filter “A” (diameter 240 mm, DIN12448-B 240) using a laboratory funnel and the solvent filtrate iscollected in a beaker underneath the funnel.

Now the remaining floating particle fraction is poured onto anotherfluted filter “B” by fully opening the stopcock and releasing the totalremaining suspension. The separating funnel has to be washed withadditional methylene chloride to rinse all particles that may besticking to the funnel into the fluted filter “B”.

As a result one obtains a sunk (fluted filter “A”) and a floatingparticle fraction (fluted filter “B”). The filtered particles are thentransferred into separate rectangular aluminium containers (16 cm×5.5cm×3.2 cm), evenly spread on the container bottom and dried for 8 hoursat 30° C. under nitrogen and reduced pressure (<100 mbar). After dryingthe content of each aluminium container is weighed resulting in the massof sunk particles (m_sunk) and the mass of floating particles (m_float).

The test result is the amount of fluid-absorbent polymer particleshaving an apparent density of less than 1.33 g/cm³ (Floating particlefraction, PFP) calculated as follows:

FPF=(m_float)/(m_float+m_sunk)×100

whereby

-   -   m_sunk is the mass of the sunk particles (fluted filter “A”),        expressed in grams    -   m_float is the mass of the floating particles (fluted filter        “B”), expressed in grams

The weight percentage is the average of two measurements. The differenceof the two measurements must be less than the higher of 2% absolute or10% relative.

Saline Flow Conductivity (SFC)

The saline flow conductivity is, as described in EP 0 640 330 A1,determined as the gel layer permeability of a swollen gel layer offluid-absorbent polymer particles, although the apparatus described onpage 19 and in FIG. 8 in the aforementioned patent application wasmodified to the effect that the glass frit (40) is no longer used, theplunger (39) consists of the same polymer material as the cylinder (37)and now comprises 21 bores having a diameter of 9.65 mm each distributeduniformly over the entire contact surface. The procedure and theevaluation of the measurement remains unchanged from EP 0 640 330 A1.The flow rate is recorded automatically.

The saline flow conductivity (SFC) is calculated as follows:

SFC[cm³s/g]=(Fg(t=0)×L0)/(d×A×WP),

where Fg(t=0) is the flow rate of NaCl solution in g/s, which isobtained by means of a linear regression analysis of the Fg(t) data ofthe flow determinations by extrapolation to t=0, L0 is the thickness ofthe gel layer in cm, d is the density of the NaCl solution in g/cm³, Ais the surface area of the gel layer in cm² and WP is the hydrostaticpressure over the gel layer in dyn/cm².

Free Swell Rate (FSR)

1.00 g (=W1) of the dry fluid-absorbent polymer particles is weighedinto a 25 ml glass beaker and is uniformly distributed on the base ofthe glass beaker. 20 ml of a 0.9% by weight sodium chloride solution arethen dispensed into a second glass beaker, the content of this beaker israpidly added to the first beaker and a stopwatch is started. As soon asthe last drop of salt solution is absorbed, confirmed by thedisappearance of the reflection on the liquid surface, the stopwatch isstopped. The exact amount of liquid poured from the second beaker andabsorbed by the polymer in the first beaker is accurately determined byweighing back the second beaker (=W2). The time needed for theabsorption, which was measured with the stopwatch, is denoted t. Thedisappearance of the last drop of liquid on the surface is defined astime t.

The free swell rate (FSR) is calculated as follows:

FSR[g/gs]=W2/(W1×t)

When the moisture content of the hydrogel-forming polymer is more than3% by weight, however, the weight W1 must be corrected for this moisturecontent.

Water Vapor Transmission Rate (WVTR)

The water vapor transmission rate (WVTR) is determined according to thetest method written in U.S. Pat. No. 6,217,890, column 32, lines 15 to56.

Anticaking

The anticaking is determined according to the test method written in WO2005/097881 A1, page 19, lines 14 to 24. For quantitative ranking gradesare given between 1 and 5, whereby grade 1 does not leave any residue inthe beaker and at grade 5 no material can be poured out of the beaker.

Residual Monomers

The level of residual monomers in the fluid-absorbent polymer particlesis determined by the EDANA recommended test method No. WSP 410.2-05“Residual Monomers”.

Particle Size Distribution

The particle size distribution of the fluid-absorbent polymer particlesis determined by the EDANA recommended) test method No. WSP 420.2-05“Particle Size Distribution”. For determination of the medium particlesize the proportions by mass of the screen fractions are plotted incumulated form and the mean particle size is determined graphically. Themean particle size here is the value of the mesh size which gives riseto a cumulative 50% by weight.

Moisture Content

The moisture content of the fluid-absorbent polymer particles isdetermined by the EDANA recommended test method No. WSP 430.2-05“Moisture Content”.

Centrifuge Retention Capacity (CRC)

The centrifuge retention capacity of the fluid-absorbent polymerparticles is determined by the EDANA recommended test method No. WSP441.2-05 “Centrifuge Retention Capacity”, wherein for higher values ofthe centrifuge retention capacity lager tea bags have to be used.

Absorbency Under Load (AUL)

The absorbency under load of the fluid-absorbent polymer particles isdetermined by the EDANA recommended test method No. WSP 442.2-05“Absorption Under Pressure”.

Absorbency Under High Load (AUHL)

The absorbency under high load of the fluid-absorbent polymer particlesis determined analogously to the EDANA recommended test method No. WSP442.2-05 “Absorption Under Pressure”, except using a weight of 49.2g/cm² instead of a weight of 21.0 g/cm².

Extractables

The level of extractable constituents in the fluid-absorbent polymerparticles is determined by the EDANA recommended test method No. WSP470.2-05 “Extractables”.

The EDANA test methods are obtainable, for example, from the EDANA,Avenue Eugène Plasky 157, B-1030 Brussels, Belgium.

EXAMPLES Preparation of the Fluid-Absorbent Polymer Particles Example 1

2.064 kg/h of acrylic acid and 18.476 kg/h of sodium acrylate (37.5% byweight solution in water) were mixed with 12.53 g/h of 3-tuplyethoxylated glycerol triacrylate (approx. 85% strength by weight). Theresulting mixture was dropletized in a heated dropletization towerfilled with a nitrogen atmosphere (height 12 m, width 2 m, gas velocity0.1 m/s in cocurrent). The metering rate of the mixture was 20.5 kg/h.The dropletizer plate had 30×200 μm bores. The initiator was meteredinto the monomer solution upstream of the dropletizer by means of astatic mixer. The initiators used were 0.67 kg/h of a 5.5% by weightsolution of 2,2′-azobis[2-(2-imidazolin-2-yl)propane]dihydrochloride inwater and 0.614 kg/h of a 3% by weight solution of sodiumperoxodisulfate in water. The heating output of the gas preheating wascontrolled such that the gas outlet temperature in the dropletizationtower was a constant 130° C.

The resulting polymer particles had a moisture content of 15.8% byweight.

Charges of 100 kg polymer particles were placed in a 2001 drum and mixedfor 2 hours and 21 rpm using a drum hoop mixer (type RRM 200; J.Engelsmann A G, Ludwig-shafen; Germany) with 0.08% by weight ofSipernat® D17 (Evonik Degussa GmbH; Frankfurt; Germany).

The resulting coated polymer particles were thermally aftertreated in afluidized bed. To this end, an air/steam mixture was flowed toward thepolymers from below for 80 minutes. The gas velocity was 0.8 m/s. Thegas temperature was 80 to 90° C. The relative moisture content of thegas stream was 25 to 35%. The gas stream comprised 0.12 to 0.15 kg ofsteam per kg of dry gas. The resulting aftertreated polymer particleswere dried in a fluidized bed for 30 minutes. The gas velocity was 0.95m/s. The gas temperature was 160° C. The relative moisture content ofthe gas stream was less than 2%.

The dried polymer particles had a moisture content of 1.9% by weight, acentrifuge retention capacity (CRC) of 36.1 g/g, an absorption underhigh load (AUHL) of 19.7 g/g, a free swell rate (FSR) of 0.66 g/gs, asaline flow conductivity (SFC) of 5×10⁻⁷ cm³s/g, a mean sphericity of0.94 and a floating particle fraction of 83%.

Example 2

Fluid-absorbent polymer particles were prepared by inverse suspensionpolymerisation according to GB 2,126,591, example 5. The dried polymerparticles had a floating particle fraction of 0%.

Preparation of the Fluid-Absorbent Cores Example 3

Fluid-absorbent core consisting of 65 wt. % fluid-absorbent polymerparticles prepared in Example 1 and 35 wt. % cellulose fluff.

Six portions of 0.583±0.001 g were weighed out of 3.5 g fluid-absorbentpolymer particles on weighing boats.

6.5 g of cellulose fluff with an addition of 0.5 g were weighed out in aweighing pan and divided into six equal portions of 1.17±0.01 g.

The fluid-absorbent core was produced as follows:

A fleece tissue was placed on a rectangular wire mesh, 17.5 cm in lengthand 11 cm in width, so that the fleece tissue covers the wire mesh. Thewire mesh was placed underneath a perpendicular shaft of the same size,where a longitudinally installed brush rotates about 68 cm above thewire mesh. At the end, 10 cm above the wire mesh, the perpendicularshaft was reduced until an inner area 16 cm in length and 9 cm in width.The brush was 17.5 cm in length and 10 cm in diameter and rotates at13.5 revolutions per second. Vacuum was sitting underneath the wire meshthat contains the fleece tissue.

The first portion of cellulose fluff was added downwardly to therotating brush. After 30 seconds, the first portion of polymer was putdownwardly onto the rotating brush.

The additions of cellulose fluff and fluid-absorbent polymer particleswere repeated in total two more times after every 30 seconds. The wiremesh with the tissue was then turned horizontally about 180°.

The additions of cellulose fluff and fluid-absorbent polymer particleswere then repeated three more times altogether.

The fluid-absorbent core was removed from the fleece tissue in such away that it was turned over very carefully on one layer of paper tissue.

A card was used to remove the adhereing particles from the fleecetissue. Then, the paper tissue (e.g. Tork® Universal Wiper 320; SCATissue Europe), 33.8 cm in length and 23.4 cm in width was folded aroundthe water-absorbing composite. The resulting water-absorbing compositewas compressed by a compactor (type Polystat 200T; Ruth SchwabenthanMaschinerifabrik; Berlin; Germany) for different times using differentpressure settings. Then the paper tissue was opened again and folded.And the water-absorbing composite was now turned horizontally about 180°and compressed again. The results are summarized in Table 1.

TABLE 1 Cores having 65 wt. % fluid-absorbent polymer particles PressureDensity of AUHL of the setting time the core isolated particles 20kg/cm² 5 seconds 0.23 g/cm³ 15.1 g/g 20 kg/cm² 3 × 15 seconds 0.34 g/cm³14.7 g/g 50 kg/cm² 3 × 15 seconds 0.37 g/cm³ 13.9 g/g

Example 4

A fluid-absorbent core consisting of 50 wt. % fluid-absorbent polymerparticles prepared in Example 1 and 50 wt. % cellulose fluff.

Six portions of 0.83±0.001 g were weighed out of 5.0 g fluid-absorbentpolymer particles on weighing boats.

5.0 g of cellulose fluff with an addition of 0.5 g were weighed out in aweighing pan and divided into six equal portions of 0.92±0.01 g.

The fluid-absorbent core was produced analogous to Example 3, complyingwith the varied weights of fluid-absorbent polymer particles andcellulose fluff.

TABLE 2 Cores having 50 wt. % fluid-absorbent polymer particles PressureDensity of AUHL of the setting time the core isolated particles 20kg/cm² 5 seconds 0.20 g/cm³ 16.4 g/g 20 kg/cm² 3 × 15 seconds 0.28 g/cm³16.1 g/g 50 kg/cm² 3 × 15 seconds 0.34 g/cm³ 12.9 g/g

Example 5

A fluid-absorbent core consisting of 35 wt. % fluid-absorbent polymerparticles prepared in Example 1 and 65 wt. % cellulose fluff.

Six portions of 1.083-±0.001 g were weighed out of 6.5 g fluid-absorbentpolymer particles on weighing boats.

3.5 g of cellulose fluff with an addition of 0.5 g were weighed out in aweighing pan and divided into six equal portions of 0.67±0.01 g.

The fluid-absorbent core was produced analogous to Example 3, complyingwith the varied weights of fluid-absorbent polymer particles andcellulose fluff.

TABLE 3 Cores having 35 wt. % fluid-absorbent polymer particles PressureDensity of AUHL of the setting time the core isolated particles 20kg/cm² 5 seconds 0.21 g/cm³ 16.4 g/g 20 kg/cm² 3 × 15 seconds 0.28 g/cm³14.0 g/g 50 kg/cm² 3 × 15 seconds 0.34 g/cm³ 13.8 g/g

The examples demonstrate that the hollow spherical fluid-absorbentpolymer particles deteriorate on pressing using high pressures and/or onpressing for a longer period of time.

Example 6

A fluid-absorbent core consisting of 65 wt % fluid-absorbent polymerparticles prepared in Example 1 and 35 wt. % cellulose fluff.

Six portions of 0.583±0.001 g were weighed out of 3.5 g fluid-absorbentpolymer particles on weighing boats.

6.5 g of cellulose fluff with an addition of 0.5 g were weighed out in aweighing pan and divided into six equal portions of 1.17±0.01 g.

The fluid-absorbent core was produced as follows:

A fleece tissue was placed on a rectangular wire mesh, 17.5 cm in lengthand 11 cm in width, so that the fleece tissue covers the wire mesh. Thewire mesh was placed underneath a perpendicular shaft of the same size,where a longitudinally installed brush rotates about 68 cm above thewire mesh. At the end, 10 cm above the wire mesh, the perpendicularshaft was reduced until an inner area 16 cm in length and 9 cm in width.The brush was 17.5 cm in (length and 10 cm in diameter and rotates at13.5 revolutions per second. Vacuum was sitting underneath the wire meshthat contains the fleece tissue.

The first portion of cellulose fluff was added downwardly to therotating brush. After 30 seconds, the first portion of polymer was putdownwardly onto the rotating brush.

The addition of cellulose fluff and fluid-absorbent polymer particleportions was repeated five times after every 30 seconds alternately.

The fluid-absorbent core was removed from the fleece tissue in such away that it was turned over very carefully on one layer of paper tissue.A card was used to remove the sticking particles from the fleece tissue.Then, the fluid-absorbent core was wrapped up in a paper tissue (e.g.Tork® Universal Wiper 320; SCA Tissue Europe), 37 cm in length and 24 cmin width. The resulting fluid-absorbent core was compressed by placing awire mesh (16 cm×9 cm, #4 mesh, supported by a frame with 2 mmthickness, 150 g) and a weight of 20 kg on top. After 5 minutes ofcompression, the weight and the wire mesh were removed and thefluid-absorbent core was unwrapped.

The unwrapped fluid-absorbent core (C) was placed on a weighed sieve 18mesh screen (mesh opening size: 1000 μm, diameter 200 millimeters) and asuitable sieve tray. By doing so, the core was turned over again, sothat the first layer of cellulose fluff was now in direct contact withthe wire mesh of the sieve.

Again, a card was used to carefully remove the remaining particles ofthe fluid-absorbent core from the paper tissue. The paper tissue wasthen completely removed.

After that the fluid-absorbent core was sieved continuously by using asieving device (e.g. AS200 control ‘g’ from Retsch®, vibratinghorizontal sieving device). The amplitude was set to 1.5 millimeters.The fluid-absorbent core was sieved for 5 minutes to see how muchfluid-absorbent core divulges in a certain sieving time.

Between this 5 minutes the sieving process was interrupted at definedintervals: The first 4 times 15 seconds and then 8 times 30 seconds. Astop watch was used to stop the different time intervals.

The sieving device was stopped between the different time intervals. Thesieve and the sieve tray were removed to weigh out the divulged mix ofcellulose fluff and fluid-absorbent polymer particles on the sieve tray.The weight (a) was noted down.

Before starting the next sieving interval the sieve tray was swunggently in orbital motion per hand to get small cellulose fluff balls.These fluff balls were then disposed with tweezers and the sieve traywas weighed again. The weight (b) was noted down, too.

The sieve containing the fluid-absorbent core was put back on top of thesieve tray, which still contains the separated fluid-absorbent polymerparticles. The next sieving interval was started.

Weight(a)=weight of cellulose fluff+fluid-absorbent polymer particles

Weight(b)=weight of segregated fluid-absorbent polymer particles

The test was repeated three times at least to get an average value.

The preferred test conditions were (23±2)° C. and (50±10) % relativehumidity.

The results are summarized in Table 4.

Example 7

Example 6 was repeated using fluid-absorbent polymer particles preparedin Examples 2.

The results are summarized in Table 4.

Example 8

A fluid-absorbent core consisting of 50 wt. % fluid-absorbent polymerparticles prepared in Example 1 and 50 wt. % cellulose fluff wasprepared using the procedure of Example 6.

Six portions of 0.83±0.001 g were weighed out of 5.0 g fluid-absorbentpolymer particles on weighing boats.

5.0 g of cellulose fluff with an addition of 0.5 g were weighed out in aweighing pan and divided into six equal portions of 0.92±0.01 g.

The fluid-absorbent core was produced analogous to Example 6, complyingwith the varied weights of fluid-absorbent polymer particles andcellulose fluff.

The results are summarized in Table 4.

Example 9

Example 8 was repeated using fluid-absorbent polymer particles preparedin Examples 2.

The results are summarized in Table 4.

Example 10

A fluid-absorbent core consisting of 35 wt. % fluid-absorbent polymerparticles prepared in Example 1 and 65 wt. % cellulose fluff.

Six portions of 1.083±0.001 g were weighed out of 6.5 g fluid-absorbentpolymer particles on weighing boats.

3.5 g of cellulose fluff with an addition of 0.5 g were weighed out in aweighing pan and divided into six equal portions of 0.67±0.01 g.

The fluid-absorbent core was produced analogous to Example 6, complyingwith the varied weights of fluid-absorbent polymer particles andcellulose fluff.

The results are summarized in Table 4.

Example 11

Example 10 was repeated using fluid-absorbent polymer particles preparedin Examples 2.

The results are summarized in Table 4.

TABLE 4 Weight of segregated fluid-absorbent polymer particles after 5minutes Example SAP weight fraction Segregated SAP particles  6 65 wt. %2.35 g  7*) 65 wt. % 2.42 g  8 50 wt. % 1.02 g  9*) 50 wt. % 1.34 g 1035 wt. % 0.61 g 11′) 35 wt. % 0.61 g *)comparative

1. A process for preparing a fluid-absorbent core, comprising (i) mixingof a fibrous material and 10 to 95% by weight of fluid-absorbent polymerparticles having a particle size of less than 1000 μm, a medium particlesize of 200 to 600 μm, a moisture content of less than 20% by weight, amean sphericity of at least 0.84 and a floating particle fraction (FPF)of at least 10%, and (ii) pressing the obtained mixture, wherein thepressing (ii) is performed that the core (C) has a density of:D<β×0.14 g/cm³+0.18 g/cm³ wherein D is the density of the core (C) and βis the weight fraction of fluid-absorbent polymer particles in the core(C).
 2. A fluid-absorbent article, comprising (A) an upperliquid-pervious layer, (B) a lower liquid-impervious layer and (C) afluid-absorbent core between the layer (A) and the layer (B), comprisinga fibrous material and 10 to 80% by weight fluid-absorbent polymerparticles having a particle size of less than 1000 μm, a medium particlesize of 200 to 600 μm, a moisture content of less than 20% by weight, amean sphericity of at least 0.84 and a floating particle fraction (FPF)of at least 10%, wherein the core (C) has a density ofD<β×0.14 g/cm³+0.18 g/cm³ wherein D is the density of the core (C) and βis the weight fraction of fluid-absorbent polymer particles in the core(C).
 3. The fluid-absorbent article according to claim 2, wherein thefluid-absorbent polymer particles have a moisture content of at least 8%by weight.
 4. The fluid-absorbent article according to claim 2, whereinthe fluid-absorbent polymer particles have a content of hydrophobicsolvents of less than 0.005% by weight.
 5. The fluid-absorbent articleaccording to claim 2, wherein the fluid-absorbent core contains at least9 g of the fluid-absorbent polymer particles.
 6. The fluid-absorbentarticle according to claim 2, wherein at least 90% by weight of thefluid-absorbent polymer particles have a diameter of from 100 to 800 μm.7. The fluid-absorbent article according to claim 2, wherein thefluid-absorbent polymer particles comprise at least partly ofpolymerized acid group-bearing monomers.
 8. The fluid-absorbent articleaccording to claim 2, wherein the fibrous material is hydrophilic. 9.The fluid-absorbent article according to claim 2, wherein thefluid-absorbent polymer particles have a centrifuge retention capacity(CRC) of at least 10 g/g.
 10. The fluid-absorbent article according toclaim 2, wherein the fluid-absorbent polymer particles have a salineflow conductivity (SFC) of at least 5×10⁻⁷ cm³s/g.
 11. Thefluid-absorbent article according to claim 2, wherein a top view area ofthe core (C) is at least 200 cm².
 12. The fluid-absorbent articleaccording to claim 2, wherein the fibrous material is a syntheticfibrous material.